MAULE M-5-220C User manual

FOR
MAULE M-5-220C
Lunar Rocket
P/N: TLC-M-5-220C
PERFORMANCE THAT COUNTS!
Rev. B Dated 04-13-16 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 M-5-220C
Rev. B 2/38
FORWARD
Ahead of you are many hours of flying pleasure. The more you fly your M-5 the more
you will realize that flying this aircraft is a stimulating new sensation that will never grow old.
The Maule M-5 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
M-5. 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
229-985-2045, Ext. 239). In correspondence, please be certain to give complete infor-
mation on serial number, engine make and model, etc.
We have gone electronic for any notification to be emailed to you affecting your air-
plane and/or manuals of a change, optional, mandatory or an optional upgrade. This will let
you know of item(s) available to download off our website at www.mauleairinc.com. Please
Send Your Email Address, Aircraft Model and S/N to [email protected].
WARRANTY
Maule Aircraft Corporation warrants each new airplane manufactured by it to be free
from defects in material and workmanship under normal use and service, provided, howev-
er, that this warranty 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 exami-
nation shall disclose to its satisfaction to have been thus defective; this warranty being ex-
pressly in lieu of all other warranties expressed or implied and all other obligations or liabili-
ties 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 and they
request that warranty claims be made through your nearest authorized Distributor or author-
ized Service Center. Maule Aircraft will be glad to help you find that facility nearest to you.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 3/38
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………….. 13
Weighing Procedure……………………………………….. 15
Rigging Procedures...............................................…..…. 17
Lubrication..............................................……………..…. 20
Fabric Repairs………………………………………….…… 21
SECTION III - MAJOR COMPONENT PARTS
Wings.....................................................................……... 22
Lift Struts......................................................................… 22
Fuselage..............................................................…..…… 22
Surfaces and Controls…………................................…… 23
Landing Gear, Wheels and Brakes.......................…...…. 24
Hoisting Wheel Views……………………………………… 26
Parking Brake Control Adjustment……………………….. 27
Maule SFS P8 Tailwheel…………………………………... 29
Power Plant System........…...................................…...… 32
Fuel System....................….............................………..… 33
Electrical System................…...................................…… 34
Electrical Schematic 14V (For s/n’s 5002C-5057C) …………..….. 36
Door Latch (old style) Adjustment Procedure………….... 37

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 4/38
LOG OF REVISIONS
Re
v. To page(s) Description Date
A
Iii
3,4
9
Added Log of revision page.
Added special maintenance procedures for floatplanes based in
coastal areas or an otherwise corrosive atmosphere.
Revised the inspection procedure concerning the horizontal stabi-
lizer strut lower attach stub tubes.
07/19/99
B 6, 21, 24, 25 Changed oleo strut oil to API GL-4 or GL-5 85W-140 gear oil. 04/13/16

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 5/38
SECTION I
GENERAL DATA
GENERAL DESCRIPTION:
Type:
Four 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 Fiberglass synthetic fabric. Fiberglass
engine cowl. Aluminum skin on forward fuselage and doors.
Landing Gear:
Main gear split axle type, spring-oil oleo shock absorber. Hydraulic
Brakes. Steerable tailwheel (Automatic locking).
Control Systems:
Dual controls wheels, rudder pedals and brakes. All controls directly
cable driven. Fuel control/shut off valve is at the left lower side pan-
el. Mechanical flap and trim controls are at the center on the floor.
All other controls, switches, etc., are instrument panel mounted.
DESIGN SPECIFICATIONS:
Wing Span 30 feet 10 inches
Length 22 feet 6 ½ inches
Height 6 feet 4 inches
Gross Weight 2300/2500* lbs.
Empty Weight Approx. 1350 lbs.
Wing Loading 14.6/15.8 lbs./sq.ft.
Power Loading 10.9/11.9 lbs./HP
Useful Load Approx.
950/1150 lbs.
Seats Four
Flaps 0°, 15°, 35°or 0°, ** 20°, **40°
Center Cargo Allowance (Sta. 42”) 175 lb. Structural Limit
Baggage Allowance (Sta. 70”) 125 lb. Structural Limit
Baggage Compartment Dimensions 30H x 26W x 21L (Approx.)
*2500 lb. gross weight is applicable if Maule Service Letter No. 51 is complied with.
**20°and 40°Flap Setting is applicable if Maule Service Letter No. 48 is complied with.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 6/38
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 157.9 sq.ft.
b. Ailerons (total) 12.8 sq.ft.
c. Flaps (total) 18.8 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 …5.8 sq.ft.
h. Elevator Trim tab 1.0 sq. ft.
i. Rudder Tab .34 sq. ft.
FLUID CAPACITIES AND SPECIFICATIONS:
a. Main Fuel Tanks - Inboard - 100 Octane
Right Main Tank 21.5 gallons total
Left Main Tank 21.5 gallons total
Note: 1.5 gallons unusable fuel per 21.5 gallon main tank
b. Auxiliary Fuel Tanks - Outboard - 100 Octane
Right Auxiliary Tank 11.5 gallons
Left Auxiliary Tank 11.5 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.)
8.8 qt.
d. Brakes (Texaco Aircraft Hydraulic Oil 15, MIL-H-5606E or equiv.)
1 pint
e. Landing Gear - For P/N 4015B oleo spring, use New Holland No.134 hydraulic
oil or Ford Tractor No. ESN-M2C134-D. 10W30 engine oil may also be used.
For P/N 4161B oleo spring use API GL-4 or GL-5 85W-140 gear oil.
2 pints

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 7/38
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 oth-
erwise 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 ai-
lerons 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 M-5-220C
Rev. B 8/38
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 dry 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 M-5-220C
Rev. B 9/38
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
MECH INSP
1. Perform appropriate inspection as called for in the engine manufacturer’s Oper-
ator's Manual.
NOTE: Check rocker box cover retaining screws for tightness and security.
2. Perform appropriate inspection as called for in the propeller manufacturer's In-
stallation, 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 32 for Brackett air filter)
7. Inspect all engine, 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 engine mount for security and cracks.
5. 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.)

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 10/38
6. Check the aileron and flap skins for cracks.
MECH INSP
7. Check the security, operation, and general condition of all control surfaces.
8. Check main landing gear oleo struts for oil leaks.
9. Drain sumps of fuel tanks.
CAUTION: Quick drains are required in all fuel tanks and if not installed, refer to Maule Service Letter
No. 32 and Service Bulletin No. 5.
10. Check general condition of Maule 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.
11. 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 Oper-
ator's Manual.
2. Perform appropriate inspection as called for in the propeller manufacturer's In-
stallation, 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. 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 rud-
der cable rub and tape has not been placed, comply with Maule SB#14 and #17.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 11/38
2. Examine all front cockpit electrical connections and wires, fuel lines and fittings,
control cable attachments and pulleys for security, leaks, chafing, etc.
MECH INSP
3. Remove rear seat, rear floorboard and panel behind baggage compartment.
4. Remove front seats and front and center floorboards.
5. Inspect all control cables, pulleys, fairings and electrical connections and wires
for security and chafing.
6. Open zippers in headliner and inspect all control cables, pulleys, fairleads and
electrical connections and wires for security and chafing.
7. Remove wing root fairings and inspect control cables, fairleads, fuel lines and
connections, and electrical wires and connections for security, chafing, and
leaks.
CAUTION: If a wing has been removed and reinstalled, or a new wing installed, visually inspect the
routing of aileron cables through the inspection hole cover located on underside of wing, aft of rear
spar and outboard of wing strut attach brackets. Ascertain that cables are not over the strut attach
bracket and that they are properly routed through the fairleads and around the pulleys.
8. Remove wing strut fairings, top and bottom, and inspect attaching fittings and
bolts for security, corrosion, and cracks. Carefully inspect both sides of lift
struts for abrasion, corrosion, pinholes, and punctures. Any paint loss or minor
corrosion should be sanded down to bare metal with fine sandpaper and metal
primer should be applied. After the primer is dried, a finish coat of the desired
color may be added. Powder coating is recommended if complete strut is being
refinished.
If powder coating exterior of sealed strut assembly, remove plug from lower end before painting. Oil-
coat internal walls of strut as follows (to be done after painting only): Inject into strut approximately
one quart of Valoil or Lionoil Multi-purpose L-1, Linseed Oil, Paralketone, LPS-3, Randolph Tube Oil
No. 315, Tubeseal (Lineoil) or any other preservative oil conforming to Federal Spec. TT-S-176D, Mil-
C-82309E, Type II or Mil-C-6708, Type I. Reinstall plug and slosh oil until interior of strut is thorough-
ly coated. Remove plug and drain oil from strut. Reinstall plug. Optional: pressure test to 4 psi +/-1
for leaks using soap solution.
WARNING: Any unrepairable dents or punctures in strut are cause for replacement of the strut.
CAUTION: If aircraft has original unsealed struts, comply with Maule Service Bulletin No. 11 (AD# 98-
15-18) as required. (New sealed struts are identified by two weld spots located at upper end. Re-
moval of the upper cuff is needed to locate the weld spots). Also, do not replace lift struts with older
M-4 struts with the 7/16” dia. lower fork. 1/2” dia. fork is required for all later models.
CAUTION: Item (a)(4) of AD# 98-15-18 is very misleading as Maule never drills holes in struts to at-
tach cuffs, door clips or any hardware and it is illegal to do so since there are no approved holes in the
wing struts under the TC data. If aircraft has a modification added requiring a drilled hole in strut un-
der a #337, refer to AD for inspection requirements at the 24-month intervals. Also, inspect the area
around the holes(s) frequently for corrosion or cracking (ref. SL#58).

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 12/38
9. Remove wheels and inspect wheels, tires, brake disc, bearings, brake lines and
brake pad for wear, cuts, chafing, leaks and general condition. Repack wheel
bearings.
MECH INSP
10. Remove landing gear top fairings and inspect attaching fittings and bolts for se-
curity, corrosion, and cracks and inspect brake hose for security, chafing and
leaks. Check oleo attach bolts for bending or shearing.
11. The oleo springs occasionally become overstressed and weak due to hard us-
age, and if so should be replaced. This can usually be detected if the airplane
sits wing low on a level surface or if the wheel camber is negative.
CAUTION: Check fluid level in the landing gear oleo struts. Fill to overflowing (no air).
CAUTION: Use Steps 10 and 11, above as a guide for inspection after an unusually hard landing or
any time there is concern about the condition of the main landing gears or their attachments.
12. Remove all inspection covers/plates and inspect all visible control cables, pul-
leys, bellcranks, electrical wires and connections, fuel lines and fittings, nuts,
bolts, etc. for security, chafing, leaks, etc.
NOTE: Check top side of rear elevator horn and cable and bottom side of forward elevator horn and
cable if yellow color-coding paint is visible. If missing, paint per Maule Service Bulletin No. 30.
13. CAUTION: At inspection hole in tail, visually check the pivoting action at the
control cable attachment points over the full range of rudder and elevator trav-
el. This action should be such that there are no bending loads imparted to the
turnbuckles (which are designed for straight tension load only).
NOTE: Any binding which causes bending of the turnbuckles should be removed. Any cable attach-
ment parts, which display appreciable corrosion, must be replaced before further flight.
NOTE: Pivot points must be cleaned and lubricated with any lightweight lubricating oil. Following lu-
brication, the cable attachments, including the turnbuckles, must be heavily coated with a good pre-
servative such as: Black Bear Paralketone Preventative/Black Bear Co./Long Island City, NY. (pre-
ferred) or LPS 3, Heavy Duty Rust Inhibitor/LPS Laboratories, Inc./Tucker, GA
NOTE: Larger stainless steel turnbuckles and corrosion resistant steel fasteners for the elevator ca-
bles are approved and recommended for airplanes operating in a potentially corrosive environment.
CAUTION - Before flight whenever elevator cables are reconnected or new cables installed: Always
check operation of elevators after a cable reconnect by pulling back on the control wheel and ascer-
tain that the elevators are in the UP position.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 13/38
CAUTION: Special attention should be given to the horizontal stabilizer lower strut attach stub tubes
which are welded to the lower longerons. The seal on the inside of the strut attach stub tubes can de-
teriorate with age which could cause corrosion on the interior of the attach stub tubes, especially on
floatplane models. It is recommended that the stabilizer struts be removed to inspect attach stub
tubes at each Annual. If there is visible external corrosion around the attach stub tubes, or the inter-
nal seal appears loose or cracked, remove the seal, clean the inside of the tube and visually inspect
the inside for corrosion. (Note: earlier model Maule airplanes used a hard seal filler material, which
may crack or lose adhesion with the tube. Later Models used silicone rubber as a seal, which is more
compliant and durable.) If corrosion is found, repair in accordance with AC 43.13-1B. After repair, or
if no corrosion is found, fill entire tube with silicone rubber to seal tube from moisture. Inspect the
struts for dents, corrosion, or punctures and replace if necessary. Reinstall struts with new hardware
and document in aircraft records.
NOTE: Double struts, available through Maule, are recommended for floatplanes and banner and
glider towing planes.
MECH INSP
14. Lubricate all chains and points of rotation on sprockets, pulleys and bellcranks.
15. Inspect and lubricate all control surface hinges and control horn connections.
16. Lubricate door hinges and latches and seat tracks.
CAUTION: Carefully inspect all door hinge bolts and nuts for condition and security. If door hinges
are secured with elastic nuts, they must be replaced with castle nuts and cotter pins. Refer to Maule
Service Letter No. 61.
17. Lubricate rudder pedals and rudder bar points of rotation.
18. Check control rigging and cable tensions.
19. Check and clean vacuum system regulator valve filter and intake filter.
20. Check the pitot static system for leaks.
21. Inspect the following components of the ME406/406HM ELT:
a. (ELT unit and mount) for proper installation and insecure mounting.
b. Wiring and conduits – for improper routing, insecure mounting, and obvi-
ous defects.
c. Bonding and shielding – for improper installation and poor condition.
d. Antenna, including trailing antenna – for poor condition, insecure mount-
ing, and improper operation.
e. Verify the battery expiration date. See below for more information con-
cerning ELT Battery.
23. Ensure that all applicable Airworthiness Directives and Maule Service Letters
and Bulletins that are mandatory have been complied with.
Periodic Maintenance for ME4 6/4 6HM ELT for the US

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 14/38
In the United States, minimum maintenance requirements for ELTs are stated in FAR 91.207 para-
graph (d):
(d) Each emergency locator transmitter required by paragraph (a) of this section must be inspected
within 12 calendar months after the last inspection for
1) Proper installation
2) Battery corrosion
3) Operation of the controls and crash sensor
4) The presence of a sufficient signal radiated from its antenna
NOTE: All references to maintenance requirements for the United States shall also apply to all ELT
users outside of the United States unless otherwise required by the installer/aircraft maintenance
procedures or the relevant national regulations.
ELT manufacturer suggests testing of the ELT every 1 to 2 months. This provides an indication of
the integrity of the ELT and antenna system. If performed at this rate, the accumulated operating
time will not reduce the 5-year life rating of the battery pack.
ELT Battery removal:
CAUTION: The battery pack contains electrostatic sensitive parts. Take ESD precautions before
handling. Damage may happen to the exposed electric parts and prevent correct operation of the
ELT. Refer to ELT Description, Operation, Installation and Maintenance Manual p/n 570-1600,
Rev. E or later, Para. 5.1 for methods of preventing an EletroStatic Discharge
1)
Remove the 8 securing screws from the battery
-
side cover. Battery pack is identified by the
e
m
bossed text: "BATTERY ACCESS ON THIS SIDE".
2) Carefully lift the battery cover (battery pack) away from the ELT and unplug the flex-cable con-
nected to the pack. Do not pull on the flexible portion of the cable - use the rigid section of the
flex circuit at the connector as a handle.
3) Inspect the battery pack and ELT chassis. The battery cells, components and connectors
should be free of corrosion. Inspect flex-circuit for broken connections or damage. Ensure
the battery housing is free of cracks or other visible damage.
4) Verify the battery expiration date. If the battery pack has not expired it may be reinstalled.
The battery pack must be replaced with a new one:
•
After use in an emergency.
•
When the transmitter has been in use for more than 1 cumulative hour; (7 flash error)
•
After an inadvertent activation of unknown duration.
•
On or before the battery replacement (expiration) date.
•
There is any evidence of corrosion or leakage of any cell or on the small interface board
and connector.
ELT Battery replacement:
1) If replacing the battery pack, order replacement kit 455-0012 which contains the battery pack
(452-6499), replacement gasket, hardware and labels. A spare label showing the expiration

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 15/38
date is included in the replacement kit. This label should be mounted in the same location as
the former expiration date label.
2) Lay the battery pack on the work surface with the batteries facing up. Install a replacement
seal in the slot along the perimeter of the housing. Leaving the battery as it is, position the
ELT over the battery pack with one hand and plug the flex-cable connector into the battery
assembly using the other. The cable should not be twisted and the connector should 'click'
into place.
Note: The battery connector is keyed to prevent incorrect installation.
WEIGHING PROCEDURE
DETAILED CALCULATIONS OF EMPTY WEIGHT AND EMPTY WEIGHT CENTER OF
GRAVITY:

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 16/38
PROCEDURE:
1. Place each of the wheels on a scale with the tailwheel elevated to place the airplane in
approximately the flight attitude.
2. Place a level on the leveling mark and leveling lug on the bottom of the right wing near
the root. Adjust the height of the tailwheel until the aircraft is level.
3. Measure the following distances:
a. Wheel base (L) - the horizontal distance from the tailwheel weight point (center of ax-
le) to the main wheel weight point (center of axle).
L = _________ Inches
b. Main Wheel Station (D) - the horizontal distance from the main wheel weight point
(center of axle) to the datum line.
D = _________ Inches
4. Measure the weights at the following points:
a. Right Main Wheel..................= ____________ Lbs.
b. Left Main Wheel....….............= ____________ Lbs.
c. Tailwheel, with tare =____________Lbs., minus tare of ______________ Lbs.
= net Tailwheel wt. (T) of _________________ Lbs.
Total Weight as Weighed (W) = __________________ Lbs.
Weighing Procedure (Cont’d)
The above empty weight includes unusable fuel of 18 lbs. at 24 inches and 5 quarts of
oil at minus 37 inches plus all items of equipment as marked on the accompanying
Equipment Lists. The certificated empty weight is the above weight less 10 lbs.
drainable oil at a minus arm of 37 inches, and for this airplane is ____________lbs.
The corresponding empty weight center of gravity is ______________inches.
5. Calculations for determining weight, C.G. and moment:
a. Center of Gravity (inches) =
L x T
- D
W
i.e., C.G. = _____________ - ____________ = ___________inches.
b. Moment (inch pounds) =
W
x C.G.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 17/38
i.e., Moment = ____________ x ___________ = __________inch lbs.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 18/38
RIGGING PROCEDURES
1.
LEVELING:
Laterally: The airplane can be accurately leveled laterally using the front spar attach bolts.
Turn these two bolts so that a flat on the head is "up". Fabricate two equal length
spacers (1½ inch minimum length) which can be placed on the bolt heads. Place
a 48 inch level across the two spacers and block under the landing gear to center
the bubble.
Longitudinally: Using a level thirty six (36) inches long or longer, place it on the leveling lug
and leveling mark thirty one (31) inches to the rear of the leveling lug on the
bottom of the right wing root. Raise the tail to bring bubble to center.
2.
DIHEDRAL ANGLE:
To check dihedral angle at the front spar, remove both top wing root fairings to expose the
front spar attach bolts. Stretch a string along the top of the wing above the front spar, from
wingtip to wingtip, and draw it tight. String can be attached to tie down fittings underneath the
wing to hold tautness. Be careful to protect the edges of the wingtips from string chafing.
Find the row of flush rivets on the top of each wing from wingtip to wingtip at the front spar
location. Measure from the forward wing to fuselage attach bolt centerline, for both left and
right wings, outboard 127.5 inches along the top of each front wing spar. Using masking tape
or equivalent, tape the string down on the rivet centerline at this point.
At the inboard end of the front spar, measure the distance from the top rear edge of the
spar cap to the string for both wings. Adjust the front wing struts so as to have a measure-
ment of 2 3/4 inches on each wing (plus or minus 1/8 inch) at this location. It is recommended
that the rear struts be removed while adjusting dihedral. The wing must be supported while
the front strut is being adjusted. For rear strut adjustment, see section on washout.
CAUTION: Be sure that the strut fork is not extended more than1 inch of threads from the
strut end to the end of the fork threads (not including the jam nut). There must be at least 1
3/8 inch of thread engagement into the strut.
3.
WASH OUT:
To adjust the wash-out in the wings, proceed as follows:
Put a leveling protractor chordwise on the underside of the wing root and adjust it to a zero
degree reading. Now put the protractor chordwise just inboard of the wing tip and adjust the
rear strut to give ½°trailing edge up, difference from the wing root angle.
4.
TAIL ASSEMBLY:
With the airplane in level position, the stabilizers should be leveled at their rear spars. The
hinge line should be straight from tip to tip. The vertical stabilizer should be plumb at the
hinge.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 19/38
5.
AILERON
S
:
Adjust the ailerons to streamline position by placing a straight edge on the bottom of the
wing chordwise at the inboard end of the aileron. Then adjust the turnbuckles in the aileron
system so the control wheels are centered and there is a gap of zero to ¼ inch between the
straight edge and the trailing edge of the aileron.
Check the aileron travel for 20°±1°up and 20°±1°down. Adjust turnbuckles to stay within
these limits. Proper cable tension is 15 to 25 lbs.
6.
FLAPS
:
Correct flap operation is dependent upon correct cable tension which is controlled by the
spring on the bellcrank in the wing. If the spring tension has diminished due to use or over
extension, this will reduce the degree of flap extension due to air loads on the flaps. If springs
appear weak, remove and check the spring tension. One inch of travel should yield a force of
twelve (12) to fifteen (15) pounds. If the tension is less than above, replace both springs with
new springs.
After verifying acceptable spring tension, check cable adjustment. Changes can be made
to the flap retract cable via the turnbuckle located behind the rear cabin bulkhead cover. Ad-
just retract cable as tight as possible without disengaging the flap lock mechanism located in
the wing at the bellcrank, if equipped. On airplanes that incorporate the flap lock mechanism,
adjustment can be checked by pushing down lightly on the trailing edge of the flap (left then
right). The flap should travel down one (1) inch ±1/4 then have a positive stop. Flap lock ad-
justment can be made at the two screws in slots on the flap lock in the wing. Without the cor-
rect travel, the lock may not be able to swing free of the stop, which will cause the flaps to not
be able to be extended.
If flap cable tension is too tight or if it does not incorporate the flap lock mechanism, the
flap will drop over three (3) inches with light downward pressure. On models that do not in-
corporate the flap lock mechanism, a limit cable is installed at the inboard flap hinge, which
should be adjusted so that the flaps will not hit the rear windows. The cable must allow the
correct full flap angle (35°or *40°depending on the ratchet).
The bellcrank in each wing should rest against the cork pad glued to the rear wing spar
while in the retracted position. While the bellcrank is in the retracted position the flaps should
be set to 0°plus or minus one half (1/2) degree using the push rod located on each flap.
To adjust the balance cable turnbuckle located above the headliner above the aileron
turnbuckles, slowly extend the flaps while watching both left and right flaps. They should ini-
tially extend evenly and together. If on the initial extension, the flaps do not extend symmetri-
cally, tighten or loosen the turnbuckle as required.
After the above adjustments have been made you should check for proper deflections: 15°
first notch and 35°second notch ±3°or *20°first notch and *40°second notch ±3°.
20°and 40°Flap Setting is applicable if Maule Service Letter No. 48 is complied with.

MAULE AEROSPACE TECHNOLOGY, INC.
MAINTENANCE MANUAL
FOR M-5-220C
Rev. B 20/38
7.
RUDDER
:
Set-up for Installation of Rudder Cables:
Lock rudder to vertical stabilizer using a C-Clamp and two (2) padded wood blocks. Es-
tablish the rudder “Neutral Position” by measuring (and holding) a distance of 6” between the
backside of the rudder pedal(s) to the face of the interior firewall. Note: Make sure the interior
(firewall) insulation and (firewall) vinyl covering/upholstery is adequately compressed during
this initial set-up phase. A wooden spacer of the appropriate length (a 2x4 wooden block
works fine) is ideal to hold the given distance during the rudder-rigging process. Install rudder
cables and related-hardware.
Check the rudder travel for 21°±1°right and left. Rudder cable tension is controlled by
springs, and the cables should not be slack with the rudder centered. Rudder trim may be ac-
complished by adjusting the tension of the rudder centering springs located behind the rear
bulkhead. Keep springs as short as possible but never less than 4 ½ inches from end coil to
end coil with the rudder centered.
8.
ELEVATORS
:
Elevator control movements are up 25°±2°, down 21°±1°. Stops are located on the verti-
cal tail rear spar just inside the inspection plate. Proper cable tension is 25 to 45 lbs.
CAUTION - BEFORE FLIGHT whenever elevator cables are reconnected or new cables in-
stalled: Always check operation of elevators after a cable reconnect by pulling back on the
control wheel and ascertain that the elevators are in the UP position.
9.
ELEVATOR TRIM
:
Elevator trim tab (without piano hinge) movement is 12°±4°up, 29°±2°down. Elevator
trim tab (with piano hinge) movement is 12°±2°up, 38°±2°down. If adjustment is needed,
it may be done at the turnbuckles located just aft of the trim control. Proper cable tension is
15 to 25 lbs.
10.
RUDDER TAB
:
This tab is interconnected with the aileron system to automatically coordinate aileron and
rudder controls for simplified handling in the air. (It may be used as a rudder trim tab to make
the airplane trim in cruise.) This tab may be adjusted by changing to the position of the tab
cables where they attach to the aileron cables located just over the front doors on the inside of
the airplane. Normally, the tab should be streamlined with the rudder when the aileron and
rudder controls are centered.
The tab travel is 48°±4°right or left. Proper cable tension is 5 to 10 lbs.
CAUTION: Make sure tab is free at extreme aileron travel.
NOTE: The “Rudder Trim Control” on the instrument panel pulls on a spring attached to the
right rudder pedal. It is not connected to the tab on the rudder.