MAULE Star Rocket M-8-235 User manual

7/99
FOR
MAULE M-8-235
Star Rocket
TLC-M-8-235
7/99
PERFORMANCE THAT COUNTS!
2099 Georgia Hwy 133 South ~ Moultrie, GA 31788
Tel: [phone] ~ Fax: [phone] ~ www.mauleairinc.com

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
i
FOREWORD
Ahead of you are many hours of flying pleasure. The more you fly your M-8 the more
you will realize that flying this aircraft is a stimulating sensation that will never grow old.
The Maule M-8 is designed and built to give you the airplane you have always want-
ed. It is fast, comfortable, and easy to fly, yet no light airplane is safer than the Maule M-8.
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
912-985-2045, Ext. 239). In correspondence, please be certain to give complete information
on serial number, engine make and model, etc.
WARRANTY
Maule Air, Inc. warrants each new airplane manufactured by it to be free from defects
in material and workmanship under normal use and service, provided, however, that this war-
ranty is limited to making good at the Maule factory any part or parts thereof which shall,
within ninety (90) days after delivery of such airplane to the original purchaser, be returned to
Maule with transportation charges prepaid, and which upon Maule's examination shall dis-
close 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 oth-
er 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 war-
ranted by McCauley Propeller, Inc., Dayton, OH. Avionics items are warranted by their man-
ufacturers. 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 M-8-235
7/99
ii
TABLE OF CONTENTS
ITEM PAGE
Forewor
d
...................................................................…… i
Warranty
...............…................................................……
i
Table of Con-
tents…..................................................…… ii
Log of Revi-
sions…................................…....................… iii
SECTION I - GENERAL DATA
General Descrip-
tion..................................……………….. 1
Design Specifica-
tions..................................................….. 1
Fluid Capacities and Specifica-
tions...........................…… 2
SECTION II - GENERAL MAINTENANCE
Cleaning and Care of Air-
craft.....................................…... 3
nspection Guides
........................................................….
5
Rigging Proce-
dures.....................................................….. 10
Lubrication
..........................................................………… 12
Fabric Re-
pairs……………………………………………….. 13
SECTION III - MAJOR COMPONENT PARTS
Wings
..........................................................................…..
14
Lift Struts
...................................................................…...
14
Fuselage
..............................................................…....….. 14
Surfaces and Con-
trols................................……………… 15
Landing Gear, Wheels and
Brakes........................……… 16

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
Maule
Tailwheel…………………………………………….. 19
Figure
One…………………………………………………… 20
Power Plant Sys-
tem........…...................................……… 21
Fuel Sys-
tem....................….............................……….….. 23
Electrical Sys-
tem................…...................................…… 24
Electrical Schematic - 14
Volt..........…......................…… 25
Electrical Schematic - 28
Volt...............................….…… 26
Door Latch Adjustment Proce-
dure....………..........…….. 27

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
1
7/99
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. Fiberglass
wing tips.
Fuselage: Welded steel tube structure.
Fuselage and tail group covered with Ceconite synthetic fabric. Fiberglass
engine cowl. Aluminum skin on forward fuselage and doors.
Landing Gear: Spring aluminum main gear. Hydraulic Brakes. Steerable tailwheel
(Automatic locking)
Control Systems: Dual controls wheels, rudder pedals and brakes. All controls direct-
ly 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 instrument panel mount-
ed.
DESIGN SPECIFICATIONS:
Wing Span 32 feet 11 inches
Length 23 feet 7½ inches
Height 6 feet 4 inches
Gross Weight 2500 lbs.
Empty Weight Approx. 1535 lbs.
Wing Loading 15.1 lbs./sq. ft.
Power Loading 10.6 lbs./HP
Useful Load Approx. 965 lbs.
Seats Four/Five
Flaps Neg. 7°, 0°, 24°, 40°
Baggage Allowance 250 lb. Structural Limit
Baggage Compartment Dimensions 35½ H x 30W x 21L

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
2
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 165.6 sq.ft.
b. Ailerons (total) 14.2 sq.ft.
c. Flaps (total) 23.9 sq.ft.
d. Horizontal Stabilizer 18.1 sq. ft.
e. Elevators (including tab) 14.1 sq. ft.
f. Vertical Stabilizer 13.1 sq. ft.
g. Rudder 6.2 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.)
O-540: 12 qt. Maximum IO-540: 8.0 qt. Maximum
9 qt. Minimum 5.0 qt. Minimum
d. Brakes (Texaco Aircraft Hydraulic Oil 15, MIL-H-5606E or equiv.)
1 pint

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
3
SECTION II
GENERAL MAINTENANCE
CLEANING AND CARE OF AIRCRAFT
Keeping the performance, speed and durability that was built into your aircraft at the
factory requires more than casual attention. The accumulation of dirt and oil on the outside
and debris 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 quality car wash with a soft cloth or sponge and plenty of clean water-do
not use dishwashing detergent. 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 electro-
static field which will attract dust to the surface. Blotting with a clean damp chamois will re-
move the charge and the dust. After cleaning, polishing with a good Plexiglas cleaning prod-
uct such as "Mirror Glaze" 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
otherwise corrosive atmosphere require special treatment to prevent corrosion, specifically
"electrolyte 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 eve-
ry effort to separate dissimilar metals with primers and coatings during manufacture, but
there are some locations (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. Periodical-
ly, coat the wings, flaps and ailerons 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.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
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Cont’d
Care should be taken in the disposal of candy wrappers, paper scraps, cigarette
butts, etc. These can work their way under the floorboards and become a fire hazard, mois-
ture trap and could jam the control cables.
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 bag-
gage compartment frequently.
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 water on textile materials.
Vinyl upholstery may be cleaned using soft whiskbroom 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 dry if water trickles through the seam stitches.
For best results, stains, especially those caused by grease or paint, should be re-
moved from upholstery as soon as possible or they may become "set" and hard or impossible
to remove. "Set" stains should be removed carefully with a clean cloth dampened in dena-
tured alcohol. Stains caused by shoe polish can best be removed with turpentine. However,
such cleaning 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 that 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 M-8-235
7/99
5
INSPECTION GUIDES
At 25 Hour Total Time, perform 50 Hour Inspection as described below:
At 50 Hour Total Time and every 50 hours thereafter:
A. POWER PLANT
1. Perform appropriate inspection as called for in the engine manufacturer's
Operator's Manual.
2. Perform appropriate inspection as called for in the propeller manufacturer's
Installation, Operation and Service Manual.
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 23 for Brackett air filter.)
7. Inspect all engine and engine mount 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 wing skins 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 before 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.)

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-8-235
7/99
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5. Check the aileron and flap skins for cracks.
6. Check the security, operation and general condition of all control surfaces.
7. Check general condition of tailwheel, leaf springs and spring attachment. Leaf
springs should have 45°angle with no weight on the wheel. Check all bolts and
nuts holding the tail springs to the fuselage. Tighten nuts, if needed, so that there is
no play or side movement in the springs or their attachment.
8. 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 engine manufacturer's Operator's
Manual.
2. Perform appropriate inspection as called for in the propeller manufacturer's Installa-
tion, Operation and Service Manual.
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. Retorque bolts attaching engine mount-to-fuselage and engine-to-engine mount.
Visually inspect mount structure for condition. See "Engine Mount" under "Power
Plant System".
7. Inspect induction system and airbox for cracks and security.
CAUTION: For carbureted engine only: If rubber seal on air valve is in poor condition,
replace seal with black nitrile rubber with cotton insert and/or if valve plate is loose, re-
pair per SB#16. (Check compliance to Maule SB#16.)
B. AIRCRAFT
1. Remove right and left kick panels in cockpit, windshield side post covers and panels
below seat fronts. 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.