1978–1985 Cessna 152 Series (152, F152, A152, FA152) Aircraft Service Manual (P/N D2064-1-13)

This Cessna service publication, P/N D2064-1-13, covers the 1978–1985 152 series, including F152, A152 Aerobat, and Reims-built FA152 aircraft. This edition contains Revision 1 (October 2, 1995), Temporary Revision 2 (January 7, 2000), and Temporary Revision 3 (March 10, 2003).

• Handling and inspections: Ground-handling procedures, lubrication charts, scheduled inspections, corrosion prevention, and storage and return-to-service instructions.

• Airframe repair: Wing, wing strut, horizontal stabilizer, and vertical fin removal and installation, with attachment inspection, nutplate replacement, and structural repair criteria.

• Flight controls: Aileron, wing flap, elevator, elevator trim tab, and rudder control-system troubleshooting and rigging, plus control-surface balancing.

• Landing gear and brakes: Nose gear shock-strut rebuilding, shimmy dampener servicing, wheel and bearing maintenance, and hydraulic brake diagnosis and bleeding.

• Engine and fuel: Engine removal and installation, ignition troubleshooting, magneto-to-engine timing, carburetor adjustment, and fuel tank and vent servicing.

• Instruments and electrical: Pitot-static leakage testing, vacuum-system diagnosis, fuel-quantity transmitter calibration, charging-system troubleshooting, and system-specific wiring diagrams.

Written as a reference for experienced aircraft mechanics, the manual also provides step-by-step procedures for mechanics with less experience.

Maintenance and Structural Repair

Ground-handling instructions cover jacking and leveling, while the cleaning sections address Alclad aluminum, acrylic windshield scratch removal, and upholstery care. The Fuselage Stations drawing and fine- and coarse-thread bolt-torque tables support component location and hardware servicing.

Structural repair coverage extends to wing skins, spars, ribs, and fuselage bulkheads. Temporary Revision 2 adds criteria for cracks in corrugated aileron and flap skins.

The wing-adjustment section warns that mishandling the eccentric bushings can impose shear loads on the attachment bolt and damage the wing-spar fitting.

STC installations: Inspection, maintenance, and parts requirements for these modifications are outside this manual's scope.

Landing Gear and Control-System Service

Wheel procedures distinguish McCauley and Cleveland assemblies. The nose gear section covers shock-strut disassembly, seal inspection, and reassembly; brake procedures include master-cylinder service and lining replacement, with MIL-H-5606 hydraulic-fluid requirements.

Control-system chapters provide cable routing, tensioning, and travel checks. The elevator trim section adds actuator disassembly and free-play inspection, while the flap section covers the motor/transmission assembly and follow-up indicating system.

Engine, Fuel, and Propeller Coverage

Powerplant procedures include oil-leak troubleshooting, engine-mount inspection, and timing for the documented Slick magneto installations. Carburetor work includes removal, installation, and idle-speed and mixture adjustment.

Repair scope: Major internal engine repairs and overhaul require separate Lycoming documentation. Carburetor overhaul and propeller repair refer to the respective manufacturers' publications; propeller and spinner removal and installation are covered here.

The Fuel System Schematic traces the tanks, venting, shutoff valve, strainer, and primer. Fuel-additive mixing charts accompany the servicing information, and Temporary Revision 3 adds a tank vent-valve tube position note.

Instrument and Electrical Diagnosis

Fuel indication: The transmitter section distinguishes Stewart-Warner calibration from nonadjustable Rochester units. This helps mechanics avoid applying the wrong calibration procedure when investigating inaccurate fuel readings.

Pitot-static inspection and leakage tests accompany Vacuum System diagrams and troubleshooting charts. The cleaning precautions explain how compressed air applied to installed vacuum-system lines can damage the gyros.

Alternator and voltage-regulator fault isolation is supported by Bus Bar/Circuit Breaker wiring diagrams and the Electrical Load Analysis Chart for circuit tracing and equipment-load checks.

Before structural or engine work, confirm that equipment and procedures meet applicable aviation requirements and heed the manual's warning about unexpected propeller movement.

A Preview of Oil-Pressure and Gyro-Vacuum Data

These operating ranges are a small selection of the engine and instrument specifications in this manual.

For the Model 152's Lycoming O-235 installation, the engine-data table lists normal oil pressure as 60–90 psi, separately from its idle and cold-start limits.

For the vacuum-driven gyro instruments, the acceptable suction-gage range is 4.6–5.4 in. Hg. The same section covers relief-valve adjustment and low-vacuum warning checks.

PDF Search, Bookmarks, and Diagram Detail

Text access and drawing clarity: An OCR text layer supports searches through the text sections, but most wiring-diagram labels are not searchable. Embedded bookmarks cover chapters and subsections. Small schematic labels require zooming, and some dense wire-table entries remain difficult to read.

The download is one 484-page printable PDF in English: 477 pages from the base publication, including its cover and front matter, plus seven Temporary Revision pages—two cover sheets and five inserted or replacement pages. All revision pages are included in the total.