MAULE MT-7-235 User manual

FOR
MAULE MT-7-235
Super Rocket
Trigear
P/N: TLC-MT-7-235
PERFORMANCE THAT COUNTS!
Page 1 of 36
Rev. D Dated 6-5-19 2099 Georgia Hwy 133 South ~ Moultrie, GA 31788
PC: SMM Tel: [phone] ~ Fax: [phone]-2048
www.mauleairinc.com

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR MT-7-235
Rev. D 2/37
FORWARD
Ahead of you are many hours of flying pleasure. The more you fly your MT-7 the
more you will realize that flying this aircraft is a stimulating new sensation that will never
grow old.
The Maule MT-7 was designed and built to give you the airplane you have always
wanted. It is fast, comfortable, and easy to fly, yet no light airplane is safer than the Maule
MT-7. Its sturdy construction means you will not have to pamper it to enjoy long years of
trouble-free service.
Our dealers and distributors are anxious to serve you and will gladly furnish advice
as to proper servicing methods. You may also address requests for information on any
items not covered in this manual to Maule Parts/Service Department of Maule Air, Inc.
(Telephone [phone], Ext. 239). In correspondence, please be certain to give com-
plete information on serial number, engine make and model, etc.
WARRANTY
Maule Air, Inc. warrants each new airplane manufactured by it to be free from de-
fects in material and workmanship under normal use and service, provided, however, that
this warranty is limited to making good at the Maule factory any part or parts thereof which
shall, within one (1) year after delivery of such airplane to the original purchaser, be re-
turned to Maule with transportation charges prepaid, and which upon Maule's examination
shall disclose to its satisfaction to have been thus defective; this warranty being expressly
in lieu of all other warranties expressed or implied and all other obligations or liabilities on
the part of Maule, and Maule neither assumes nor authorizes any other person to assume
for it any other liability in connection with the sale of its airplane.
This warranty shall not apply to any airplane which shall have been repaired or al-
tered outside Maule's factory in any way so as, in Maule's judgment, to affect the airplane’s
stability or reliability, or which airplane has been subject to
misuse, negligence or accident.
Certain items of equipment are warranted separately by their manufacturer. The en-
gine and accessories are warranted by Textron Lycoming, Williamsport, PA. The Hartzell
Propeller is warranted by Hartzell Propeller, Inc., Piqua, OH, the McCauley Propeller is
warranted by McCauley Propeller, Inc., Dayton, OH. Avionics items are warranted by their
manufacturers. Manufacturers of separately warranted item of equipment request that
warranty claims be made through your nearest authorized Distributor or authorized Service
Center. Maule Air will be glad to help you find that facility nearest to you.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR MT-7-235
Rev. D 3/37
TABLE OF CONTENTS
ITEM PAGE
Cover…………………………………………………………
1
Foreword...................................................................…... 2
Warranty...............…................................................….…
2
Table of
Contents….........................................................
3
Log of Revisions….....................................................….. 4
SECTION I - GENERAL DATA
General Description....................................................….. 5
Design Specification...................................................…..
5
Fluid Capacities and
Specification..............................….
6
SECTION II - GENERAL MAINTENANCE
Cleaning and Care of Aircraft.........................….........….
7
Inspection Guides.......................................................…. 9
Periodic
Maintenance
for ME406/406HM ELT
…………..
1
2
Weighing Procedure………………………………………..
15
Rigging Procedures...............................................…..…. 17
Lubrication..........
....................................……………..….
1
9
Fabric Repairs………………………………………….…… 20
SECTION III - MAJOR COMPONENT PARTS
Wings.....................................................................……...
2
1
Lift Struts......................................................................… 21
Fuselage..............................................................…..……
2
1
Movable Surfaces and Controls................................…… 22
Landing Gear, Wheels and Brakes.......................…...….
2
3
Hoisting Wheel Views………………………………………
2
4
Parking Brake Control Adjustment……………………….. 25
Nosewheel and Nosewheel Oleo Strut
……
………
……..
.
2
7
Power Plant System........…...................................…...… 28
Fuel System....................….............................………..…
30
Electrical
System................…...................................……
31
Electrical Schematic…14V………………………...………. 32
Electrical Schematic…14V…
…………………………
..
….
33
Electrical Schematic…28V….......……….………………... 34
Door Latch (old style) Adjustment Procedure....…………
35
Airworthiness Limitations Section…………………………
36

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR MT-7-235
Rev. D 4/37
LOG OF REVISIONS
Rev. To
page(s)
Description Date
A
iii
3, 4
9
Added Log of revision page iii.
Added special maintenance procedures for floatplanes
based in coastal areas or an otherwise corrosive atmos-
phere.
Revised the inspection procedure concerning the horizontal
stabilizer strut lower attach stub tubes.
07/19/99
B
24
24a
Added applicable Serial Numbers 18001C-18041C,
18044C, 18046C-18048C to Electrical Schematic on page
26.
Added Electrical Schematic for Serial Numbers 18042C,
18043C, 18045C, 18049C & up.
09/20/00
C
5
6
9
10
11
12
13
15
18
23
24
25
Baggage/Cargo Allowance changed to 125 lb. and 175 lb.
Structural Limit.
Areas corrected.
Added Textron Lycoming, Hartzell and McCauley Manual
part numbers. Added Item B.4, the removal of front seats
and front and center floorboards for good visual inspection
beneath.
Added instructions for re-oiling and powder coating wing
struts.
Added caution note when reconnecting elevator cables.
Added visual inspection of color-coding paint for elevator
horns and cables.
Added Periodic Maintenance for ME406/406HM ELT.
Added weighing procedures.
Added set-up for installation of rudder cables.
Added torque requirement to Item 13.
Added wheel hoisting views.
Added parking brake control system inspection and adjust-
ing instructions.
09/12/11
D 12
Added statement for Service Letter #74. Differentiated be-
tween old AN and new NAS bolts. Changed torque value
from 450-500 inch pounds to 240-300 inch pounds.
Removed NOTE for Service Letter #66.
06/05/19

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR MT-7-235
Rev. D 5/37
SECTION I
GENERAL DATA
GENERAL DESCRIPTION:
Type: Five place high wing cabin monoplane.
Engine Installation: Single tractor engine in nose of fuselage.
Wing:
Strut braced, two spar, metal covered, modified USA 35-B airfoil. Fi-
berglass wing tips.
Fuselage: elded steel tube structure.
Fuselage and tail group covered with Ceconite
synthetic fabric.
Fiberglass engine cowl. Aluminum skin on forward fuselage and
doors.
Landing Gear:
Air-oil nosewheel oleo strut, steerable from rudder pedals.
Spring aluminum main gear. Hydraulic Brakes.
Control Systems: Dual controls wheels, rudder pedals and brakes. All con-
trols directly cable driven. Fuel control/shut off valve is at
the left lower side panel. Mechanical flap and trim controls
are at the center on the floor. All other controls, switches,
etc., are instru
ment panel mounted.
DESIGN SPECIFICATIONS:
Wing Span 32 feet 11 inches
Length 23 feet 7½ inches
Height 6 feet 10 inches over wing
8 feet 4 inches over rudder
Gross Weight 2500 lbs.
Empty Weight Approx. 1570 lbs.
Wing Loading 15.1 lbs./sq.ft.
Power Loading 10.6 lbs./HP
Useful Load Approx. 930 lbs.
Seats Five
Flaps Neg. 7°, 0°, 24°, 40°
Center Cargo Allowance (Sta. 42”) 175 lb. Structural Limit
Baggage Allowance (Sta. 72”) 125 lb. Structural Limit
Baggage Compartment Dimensions 38H x 32 x 27L (Approx.)

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR MT-7-235
Rev. D 6/37
DESIGN SPECIFICATIONS: (Cont’d)
Wings:
a.
Airfoil Modified USA 35-B
b.
Chord 63 inches
c.
Incidence +30 minutes
d.
Dihedral 1.2 degrees
e.
Sweepback None
Areas:
a.
Wing, Aileron and Flaps 173.7 sq.ft.
b.
Ailerons (total) 14.2 sq.ft.
c.
Flaps (total) 23.9 sq. ft.
d.
Horizontal Stabilizer 14.2 sq. ft.
e.
Elevators (including tab) 15.7 sq. ft.
f.
Vertical Stabilizer 12.9 sq. ft.
g.
Rudder 6.4 sq. ft.
h.
Elevator Trim tab 1.03 sq. ft.
i.
Rudder Tab .34 sq. ft.
FLUID CAPACITIES AND SPECIFICATIONS:
a. Main Fuel Tanks - Inboard - 100 Octane
Right Main Tank
21.5 or 23.8 gallons total
Left Main Tank 21.5 or 23.8 gallons total
Note: 1.5 gallons unusable fuel per 21.5 gallon main tank
2.3 gallons unusable fuel per 23.8 gallon main tank
b. Auxiliary Fuel Tanks - Outboard - 100 Octane
Right Auxiliary Tank 15.0 gallons or 21.0 gallons
Left Auxiliary Tank
15.0 gallons or 21.0 gallons
c. Engine Oil (SAE 50 above 60°F, SAE 40 at 30°to 90°F, SAE 20 below
10°F ambient air temp. at sea level. Refer to Engine Manual for
AD Oil grades.)
8.0 qt. Maximum
5.0 qt. Minimum
d.
Brakes
(Texaco Aircraft Hydraulic Oil 15, MIL
-
H
-
5606E or equiv.)
1 pint
e. Nosewheel Oleo Strut (Hydraulic Fluid, Texaco Aircraft Hydraulic Oil 15,
Mil-H-5606 or equiv.)

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR MT-7-235
Rev. D 7/37
2 pints (approx.)
SECTION II
GENERAL MAINTENANCE
CLEANING AND CARE OF AIRCRAFT
Keeping the performance, speed and durability that was built into your aircraft at the fac-
tory requires more than casual attention. The accumulation of dirt and oil on the outside and de-
bris inside does affect these factors and can be a fire hazard as well. The first step to proper
maintenance is a clean aircraft.
EXTERIOR
Frequent washing is good for your aircraft finish, especially during the first few months.
Use any car soap or detergent with a soft cloth or sponge and plenty of clean water. Drying
should be done with a chamois. Accumulation of oil, grease and exhaust carbon deposits should
be removed frequently by using a soft cloth soaked in mineral spirits or other neutral cleaner.
For general polishing, apply a good quality car polish or wax according to instructions.
Clean Plexiglas with plenty of soap and water using grit free soft cloth, chamois or sponge. Use
of a dry cloth on Plexiglas will not only cause scratches but will also build up an electrostatic field
which will attract dust to the surface. Blotting with a clean damp chamois will remove the charge
and the dust. After cleaning, polishing with a good Plexiglas cleaning product such as "Mirror
Glaz" will keep the glass clean and help polish out minor scratches.
Experience has shown that airplanes based at coastal airports or where there is an other-
wise corrosive atmosphere require special treatment to prevent corrosion, specifically "electro-
lyte corrosion". Salt water and chemicals act as an electrolyte between dissimilar metals and
can start a strong corrosive action over a short period of time. Maule makes every effort to sepa-
rate dissimilar metals with primers and coatings during manufacture, but there are some loca-
tions (such as rivets in wing skins) where this is impossible. To combat corrosion it is important
that the external painted surfaces be kept clean and well waxed. Wash the airplane with fresh
water frequently to remove any salt or chemical film. Periodically, coat the wings, flaps and ailer-
ons internally with a quality corrosion preventative, several of which are available. Floatplanes
require more extensive preservation techniques, which are well known in the field.
INTERIOR
Floorboards should be vacuumed frequently and can be cleaned with any good rug
cleaner.
Care should be taken in the disposal of candy wrappers, paper scraps, etc. These can
work their way under the floorboards and become a fire hazard and moisture trap.
NOTE: While washing the aircraft, ascertain that all drain holes are open. Clean out any debris
blocking them. Accumulated water can be dangerous, so check behind the baggage compart-
ment frequently.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR MT-7-235
Rev. D 8/37
INTERIOR (Cont’d)
Textile upholstery may be cleaned using a vacuum cleaner. Grease and oil spots on the
upholstery should be treated with a spot remover or dry cleaning fluid. Do not use soap and wa-
ter on textile materials.
Vinyl upholstery may be cleaned using soft whisk broom or suds of any mild soap (castile
or olive oil base) in lukewarm water. Use water sparingly as the upholstery otherwise requires a
long time to dr
y if water trickles through the seam stitches.
For best results, stains, especially those caused by grease or paint, should be removed
from upholstery as soon as possible or they may become “set”" and hard or impossible to re-
move. "Set" stains should be removed carefully with a clean cloth dampened in denatured alco-
hol. Stains caused by shoe polish can best be removed with turpentine. However, such clean-
ing agents are liable to affect the dust-repellent finish of the vinyl if used in excess of the actual
requirements. Never use volatile solvents such as lacquer thinner, acetone, etc. on upholstery.
The cleaning should be completed by wiping the surface of the vinyl dry with a clean
cloth, particularly in the seam. No attempt should be made to apply preservatives such as wax,
polish, or varnishes, as these will not be absorbed by vinyl, but will merely collect dust. There
are protective treatments made especially for vinyl, which are commercially available and quite
satisfactory.
Leather upholstery should be cleaned by leather cleaning methods using leather-cleaning
products.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR MT-7-235
Rev. D 9/37
INSPECTION GUIDES
At
25 Hour Total Time,
p
erform
50 Hour
Inspection as described below:
At
50 Hour Total Time
and every
50 hours
thereafter:
A. POWER PLANT
MECH INSP
1. Perform appropriate inspection as called for in the Textron Lycoming Operator's
Manual, p/n 60297-9, Initial Revision or later.
2. Perform appropriate inspection as called for in the Hartzell Owner’s Manual and
Logbook, p/n 7998-115N, Revision 14 or later or McCauley Owner’s Manual,
p/n MPC-11, Initial Revision or later.
3. Remove the outer muffs from the mufflers and inspect the mufflers and tubes
for cracks. Inspect muffs for cracks before reinstalling.
4. Inspect gascolator, clean if necessary.
5. Inspect engine controls for security and proper operation.
6. Clean or replace air filter. (See page 31 for Brackett air filter)
7. Inspect all engine, engine mount and nosewheel structure attach bolts.
8. Inspect all engine fuel and oil lines for general condition and security.
9. Check all engine compartment electrical connections and wires for security and
chafing.
B. AIRCRAFT
1. Check battery for general condition and electrolyte level, (in wet cell batteries
only).
2. Check all main electrical connections.
3. Check fluid level in brake reservoirs.
4. Check the entire fuselage, tail surfaces, and wings for cracks, security of fair-
ings and general condition.
CAUTION: If airplane is subject to excessive stress, i.e., heavy loads, adverse wind conditions, rough
landings, etc., take special care in examining wing skins for any cracks. If any are found, repair be-
fore further flight in accordance with AC 43:13 and factory drawings. (Do not replace any countersunk
rivets with buttonhead rivets in wing because it is not approved.)
5. Check the aileron and flap skins for cracks.
6. Check the security, operation, and general condition of all control surfaces.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR MT-7-235
Rev. D 10/37
7. Check nosewheel landing gear oleo strut for indication of oil leaks. See Section
III for service instructions.
MECH INSP
8. Check general condition of nosewheel, steering linkage, scissors and shimmy
damper. Check main landing gear for condition and brakes for leakage and
wear.
7. Drain sumps of fuel tanks.
9. Check tires for inflation and cuts.
At 100 Hours Total Time and every 100 Hours thereafter, perform the 50 hour inspection plus the
following:
A. POWER PLANT
1. Perform appropriate inspection as called for in the Textron Lycoming Operator's
Manual, p/n 60297-9, Initial Revision or later.
2. Perform appropriate inspection as called for in the Hartzell Owner’s Manual and
Logbook, p/n 7998-115N, Revision 14 or later or McCauley Owner’s Manual,
p/n MPC-11, Initial Revision or later.
3. Clean the engine with any good engine cleaner (Gunk, etc.) Be sure to protect
magneto from getting wet.
4. Examine baffles and baffle extensions for security and cracking.
5. Clean gascolator screen.
6. Re-torque bolts attaching engine mount-to-fuselage, engine-to-engine mount.
Visually inspect mount structure for condition. See "Engine Mount" under
"Power Plant System".
7. Inspect induction system and air box for cracks and security.
B. AIRCRAFT
1. Remove right and left kick panels in cockpit, windshield side post covers and
panels below seat fronts. Examine rudder cables (located behind kick panels)
and attaching clamps, bolts and nuts for security and general condition.
CAUTION: If cable guide tubes are not installed and if backside of kick panel
shows evidence of rudder cable rub and tape has not been placed, comply with
Maule SB#14 and #17.
2. Examine all front cockpit electrical connections and wires, fuel lines and fittings,
control cable attachments and pulleys for security, leaks, chafing, etc.
3. Remove rear seat, rear floorboard and panel behind baggage compartment.