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MAULE AIRCRAFT CORPORATION 

MAINTENANCE MANUAL 

FOR 

M-4/C/S/T

 

 

 

Rev. B 
4/13/16 

quirements at the 24-month intervals.  Also, inspect the area around the holes(s) fre-
quently for corrosion or cracking (ref. Maule Service Letter #58). 
 
8.  Remove wheels and inspect wheels, tires, brake drums/disc, bearings, brake lines 

and brake pad for wear, cuts, chafing, leaks and general condition.  Repack wheel 
bearings. 

 

9.  Remove landing gear top fairings and inspect attaching fittings and bolts for securi-

ty, corrosion and cracks and inspect brake hose for security, chafing and leaks.  
Check oleo attach bolts for bending or shearing. 

 

10.  The oleo springs occasionally become overstressed and weak due to hard usage, 

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 9 and 10 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. 

 

11.  Remove all inspection covers/plates and inspect all visible control cables, pulleys, 

bellcranks, electrical wires and connections, fuel lines and fittings, nuts, bolts, etc. 
for security, chafing, leaks, etc.   

 

12.  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 travel.  This ac-
tion should be such that there are no bending loads imparted to the turnbuckles, 
(which are designed for straight tension load only).  Any binding which causes 
bending of the turnbuckles should be removed.  Any cable attachment 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 
lubrication, the cable attachments, including the turnbuckles, must be heavily coat-
ed with a good preservative such as:  
 
Black Bear Paralketone Preventative  

LPS 3, Heavy Duty Rust Inhibitor 

Black Bear Co.   (preferred)  

LPS Laboratories, Inc. 

Long Island City, NY   

Tucker, GA 

 

NOTE: Maule Service Bulletin No. 9 covers corrosion resistant parts replacement and is 
particularly recommended for airplanes operating in a potentially corrosive environment.  
Compliance to this Service Bulletin provides for larger stainless steel turnbuckles and 
corrosion resistant steel fasteners and attachment details for the elevator cables. 

 

   
13.  Lubricate all chains and points of rotation on sprockets, pulleys and bellcranks, 

 

14.  Inspect and lubricate all control surface hinges and control horn connections. 

 

Summary of Contents for Jetasen M-4

Page 1: ...Rev B 4 13 16 FOR MAULE M 4 M 4C M 4S and M 4T Jetasen...

Page 2: ...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 ninety 90 days af...

Page 3: ...Specifications 2 SECTION II GENERAL MAINTENANCE Cleaning and Care of Aircraft 3 Inspection Guides 5 Rigging Procedures 10 Lubrication 13 Fabric Repairs 14 SECTION III MAJOR COMPONENT PARTS Wings 15 L...

Page 4: ...Brakes Steerable tailwheel Automatic locking Control Systems Dual controls wheels and rudder pedals All controls directly cable driven Fuel control shut off valve is at the left lower side panel Mech...

Page 5: ...1 0 gallons total Left Main Tank 21 0 gallons total Note 1 5 gallons unusable fuel per main tank b Auxiliary Fuel Tanks if installed Outboard 100 Octane Right Auxiliary Tank 11 5 gallons Left Auxiliar...

Page 6: ...ld 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 pro...

Page 7: ...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...

Page 8: ...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 pag...

Page 9: ...d so that there is no play or side movement in the springs or their attachment 9 Drain sumps of fuel tanks CAUTION Quick drains are required in all fuel tanks and if not installed comply with Maule Se...

Page 10: ...trical wires and connections for security chafing and leaks 7 Remove wing strut fairings top and bottom and inspect attaching fittings and bolts for security corrosion and cracks Carefully inspect bot...

Page 11: ...ections fuel lines and fittings nuts bolts etc for security chafing leaks etc 12 CAUTION At inspection hole in tail visually check the pivoting action at the control cable attachment points over the f...

Page 12: ...r hinges they must be replaced with castle nuts and cotter pins Refer to Maule Service Letter No 61 16 Lubricate rudder pedals and rudder bar points of rotation 17 Check control rigging and cable tens...

Page 13: ...ivets 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 al...

Page 14: ...inch of travel should yield a force of twelve 12 to fifteen 15 pounds If the tension is less than above re place both springs with new springs After verifying acceptable spring tension check cable ad...

Page 15: ...ith wheel type trim control if installed movement is 11 3 up 25 1 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 l...

Page 16: ...y light coat of graphite base lubricant to aileron balance chain torque tube and control guide Use lightweight lubricating oil on all other bearings 5 Control pulley bearings and control surface hinge...

Page 17: ...ir patch 6 Allow prime to dry for 4 hours 7 Apply a coat of urethane adhesive thinned one to one 1 1 with urethane adhesive thin ner by volume to the primed area slightly larger than the repair patch...

Page 18: ...efinished WARNING Any unrepairable dents or punctures are cause for replacement of the strut If airplane has the original unsealed struts insure compliance with AD No 98 15 18 Maule SB No 11 See also...

Page 19: ...stabilizers have chrome molybdenum steel 4130 internal structures covered with fiberglass fabric Inspect for corrosion including elevator hinges and struts Steel tie rods brace the stabilizers to the...

Page 20: ...s supported by two spring oil type oleo struts which must be full of oil at all times The oil may be checked by removing a 1 8 pipe plug at the top end of the strut If oil is needed for P N 4015B oleo...

Page 21: ...hrome molybdenum steel 4130 and has an aluminum skin 2024 T3 These need no maintenance other than inspection for corrosion The hinges should be lubricated every hundred hours using a light engine oil...

Page 22: ...rake pads Replace if necessary 17 Replace brake calipers and hub cap BRAKE CYLINDERS The hydraulic brakes are actuated by two 2 master cylinders Scott p n 4408C on the left side and two 2 slave cylind...

Page 23: ...nspect at regular intervals and keep reser voir full at all times 5 Vent plug stopped up 5 If vent hole in reservoir plug becomes stopped there is a possibility that a partial vacuum will be created i...

Page 24: ...ASSEMBLY 1 Remove cap 74B may be pried off with flat side of a screwdriver 2 Hold the fork 69B and loosen the nut A1 3 With the nut removed carefully remove the fork spindle from the rest of the as se...

Page 25: ...RCRAFT CORPORATION MAINTENANCE MANUAL FOR M 4 C S T 22 Rev B 4 13 16 1 or two 2 shims will be required to remove any bearing clearance Too many shims will cause the bearings to drag when the nut is ti...

Page 26: ...73B arm 6 with lock pin 13AB and spring 14 installed shield 36 and pins 60AB together as a unit Make sure that the key end of lock pin 13AB is properly aligned with the slot in lock ring 73B 6 Slide...

Page 27: ...on of the rubber mounts At regular intervals the attaching bolts at the engine should be checked for tightness required torque value of 37 5 41 5 ft lb The rubber en gine mounts should be carefully in...

Page 28: ...SYSTEM Check mufflers and tailpipes for cracks Check attachments for security Note that the tailpipe clamps and the muffler to header attachments should not be tightened to the point of rigidity but...

Page 29: ...r 35 amperes as per generator A 20 or 35 amp circuit breaker is installed in aircraft BATTERY A lead plate type storage battery rated at 12 volts is installed in the battery box attached to the forwar...

Page 30: ...MAULE AIRCRAFT CORPORATION MAINTENANCE MANUAL FOR M 4 C S T Rev B 4 13 16 27 Electrical Schematic 14 Volt...

Page 31: ...e s Description Date A iii 3 4 Added Log of revision page iii Added special maintenance procedures for floatplanes based in coastal areas or an otherwise corrosive atmosphere 07 19 99 B 2 13 17 Added...

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