INSTALLATION INSTRUCTIONS

MAULE M-6 · Maintenance Manual

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Overview

This document provides installation instructions for aluminum lift struts designed for the Maule Series aircraft. It includes details on the removal of existing steel struts, installation of the new aluminum struts, and necessary adjustments for weight and balance.

The manual is proprietary to Airframes Alaska, LLC.
Installation requires two people for safety.
Aluminum struts are lighter than OEM steel struts.
Powder coating is not acceptable for aluminum struts.
Strut fairings may require trimming for proper fit.
Weight reduction is significant when replacing steel struts.
Proper rigging is essential after installation.
The manual includes troubleshooting and engineering change procedures.

Document

Source

Originally published by alaskagearcompany.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.

View original at alaskagearcompany.com

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Document details

Type: Maintenance Manual
Year: 2021
File size: 585 KB
Publisher: alaskagearcompany.com
Language: en

Specifications & performance

Extracted from this document.

Specifications

Aluminum rear strut weight (lb): 6.29
Aluminum front strut weight (lb): 6.79
Weight reduction oem maule struts (lb): 8
Weight reduction sealed steel struts (lb): 8.4
Strut location aft of wing leading edge (in): 17

About this document

What is the INSTALLATION INSTRUCTIONS?

The INSTALLATION INSTRUCTIONS is a maintenance manual for the MAULE M-6, dated 2021.

Where does the INSTALLATION INSTRUCTIONS come from?

This copy of the INSTALLATION INSTRUCTIONS was originally published by alaskagearcompany.com and is hosted on Sprinkle as a free, searchable reference copy.

What year was the INSTALLATION INSTRUCTIONS published?

The INSTALLATION INSTRUCTIONS — the MAULE M-6 maintenance manual on file — is dated 2021.

Documentation completeness

1/7

Most owners only have the POH. Here's the essential set for the MAULE M-6.

Pilot's Operating Handbook / AFM
Checklist
Maintenance Manual
Parts Catalog (IPC)
Systems & Wiring
Service Bulletins on file
Type Certificate (TCDS)

More MAULE M-6manuals & documents

In this document

Background

The aluminum lift strut is a lightweight replacement that prevents corrosion issues associated with steel struts.

Installation Instructions

Detailed steps for removing steel struts and installing aluminum struts, including safety precautions and necessary tools.

Weight and Balance

The aluminum struts reduce aircraft weight by 8.4 lbs when replacing sealed steel struts and 8 lbs when replacing OEM Maule struts.

Trouble Shooting

This section will be updated with common problems and corrections as they arise.

Documents and Drawings

Lists relevant documents and drawings related to the installation and maintenance of the struts.

Engineering Changes and Amendments

Outlines the process for notifying owners of changes affecting airworthiness.

Safety notes

Powder coating of heat-treated aluminum struts could alter their strength.
Ensure proper rigging after installation to maintain aircraft performance.
Use caution when handling struts to avoid damage during installation.

Full document text

1 INSTALLATION INSTRUCTIONS Aircraft: Maule Series ALUMINUM LIFT STRUTS Release Number: B Release Date: 5/7/2021 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA. 907.331.4480 // AIRFRAMESALASKA.COM // 81 E. COMMERCIAL DRIVE, PALMER, AK, 99645 2 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. This Page Intentionally Left Blank 3 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. Record of Revisions Rev Level Date Page Author Explanation of Revisions IR 12/4/2020 - Jon Earl Initial Release A 1/21/2021 7 Jon Earl Added weight comparison between OEM Maule struts and aluminum Maule struts. B 5/7/2021 5 Jon Earl Removed AD Statement. Distribution of Changes A current copy of this manual will be maintained on the Airframes Alaska, LLC. website. 4 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. Table of Contents 1 Background............................................................................................................... 5 2 Installation Instructions ............................................................................................. 5 3 Weight and Balance............................................................................................... 10 4 Trouble Shooting .................................................................................................... 10 5 Documents and Drawings .......................................................................................11 6 Engineering Changes and Amendments ................................................................12 5 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. 1 Background This lightweight aluminum replacement lift strut utilizes an aluminum extrusion with open ends, corrosion will not be an issue as with the non-sealed OEM steel struts. 2 Installation Instructions (to accomplish lift strut removal and installation properly, two people will be required) If the aircraft has steel lift struts in place, they need to be removed as outlined below: 1. Remove top and bottom wing strut fairings. 2. Remove the front and rear strut fasteners from the fuselage by removing the bolts, nuts, and cotter pins at the lower end of each strut. 3. With one person at the wing tip holding the wing tip up. Disconnect the rear lift strut from the wing panel by removing the bolt, washer, and nut. 4. Pull the rear strut off the fuselage and place it out of the way in a safe location. 5. While one person is still holding the wing tip up, disconnect the front lift strut from the wing panel by removing the bolt, washer, nut, spacer, and pulley housing. 6. Pull the front strut off the fuselage and place it out of the way in a safe location. 7. It may be necessary to prop the wing tip up with a stand if the new aluminum struts are not prepared and immediately ready for installation. Installation of the new aluminum lift struts (if the aircraft flew straight and level and was properly rigged prior to removal of the steel struts, adjust the new aluminum forks exactly like the forks on the steel struts. Note: there must not be more than 15 threads showing external to the strut.) 6 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. Caution: Powder coating of heat-treated Aluminum struts could alter their strength; therefore powder coating is not acceptable. These aluminum struts must be finished with conventional liquid paint or left in their bare aluminum state only. 1. With one person at the wing tip holding up the wing, install the new aluminum front strut to the wing panel. Note: The new aluminum front and rear lift struts are interchangeable so there is not a dedicated left-hand or right-hand strut. Use the same bolt, nut, washer, spacer, and pulley housing that was removed from the front steel strut. Secure the nut onto the bolt. 2. The person holding up the tip will need to raise the tip up so that the fork end of the front strut can be guided and aligned to the front strut hole on the fuselage strut fitting (be careful not to damage the strut during the installation process). 3. Once the new front strut in in place, replace the fork bolt, nut, and use a new cotter pin to secure it in place at the fuselage strut fitting. The wing will now be stable and the person holding up the tip can release it without fear of the wing panel dropping. 4. Mount the new aluminum rear strut to the rear hole on the fuselage strut fitting. 5. With one person holding the wing tip trialing edge, mount the rear strut to the wing panel. The person holding the wing tip trailing edge will likely have to either raise or lower the tip to mate the rear strut to the wing panel. 6. Using the same bolts, nuts, and washers removed from the steel strut, reinstall and secure with a new cotter pin. If the aircraft flew straight and level and was properly rigged prior to removal of the steel struts and the fork positions were replicated proceed to the next step. If not, the aircraft will need to be properly rigged, go to the rigging instruction below prior to proceeding any further.

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7. The aluminum struts have a slightly larger profile than the original factory part. If strut fairings are used, some minor trimming and adjustment of the fairings may be required to allow a proper fit with the strut. 8. Install door stop clamps on the rear struts. 7 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. After the new aluminum struts are properly installed check for proper wing rigging as follows: 1. Level the aircraft laterally and longitudinally. Refer to the Maule maintenance manual for the model of your aircraft. 2. Dihedral Angle. Refer to the Maule maintenance manual for the model of your aircraft. 3. Washout. Refer to the Maule maintenance manual for the model of your aircraft. 3 Weight and Balance The replacement Maule aluminum lift strut exchange weight is significant and will require changes to the aircraft Weight and Balance after installing this STC. If replacing Airframes sealed steel struts, the aircraft weight is reduced by: 8.4 lbs. If replacing OEM Maule struts, the aircraft weight is reduced by: 8 lbs. The Aluminum Front Maule Strut weighs: 6.79 lbs. The Aluminum Rear Maule Strut weighs: 6.29 lbs. The struts are located 17” aft of the wing leading edge datum 8 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. 4 Trouble Shooting To be updated with common Problems and Corrections if necessary when and if they arise when more kits are installed in the field. 5 Documents and Drawings Descriptive Data List Document Title Document Number Revision Level Pages Date Instructions for Continued Airworthiness ICA A 5/7/2021 Maule Aluminum Front Lift Strut Assembly Drawing AF51601 IR 12/30/2019 Maule Aluminum Rear Lift Strut Assembly Drawing AF51602 IR 1/2/2020 9 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. 10 THIS MANUAL INCLUDES INFORMATION PROPRIETY TO AIRFRAMES ALASKA, LLC. AND SHALL NOT BE USED TO MANUFACTURE OR REPRODUCE ANY PART OR ASSEMBLY WITHOUT THE PRIOR WRITTERN PERMISSION OF AIRFRAMES ALASKA, LLC. 6 Engineering Changes and Amendments In the event that a change or amendment is made to the design, components, or procedures contained within this manual or STC that affect airworthiness of the installation; Airframes Alaska, LLC. will notify the recorded owners in writing of the affected element(s) and provide the necessary data for compliance. 907.331.4480 // AIRFRAMESALASKA.COM // 81 E. COMMERCIAL DRIVE, PALMER, AK, 99645

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