Model 152 Series 1978 Thru 1985 Service Manual

2-17thru2-18 ................... 0 5-42 ............................ 0 * 2-18A .......................... 1 * 5-43 ............................ 1 2-18B ........................... 0 5-44 Blank ...................... 0 2-19 ............................ 0 * 6-1 ........................ 1 * 2-20 ............................ 1 6-2 thru 6-9 ..................... 0 * 2-21 ............................ 1 * 6-10thru 6-11 ................... 1 2-22 ............................ 0 6-12 B lank ...................... 0 * 2-23 thru 2-27 ................... 1 * 7-1 ............................. 1 2-28 thru 2-35 ................... 0 7-2 thru 7-5 ..................... 0 * 2-36 thru 2-38 ................... 1 7-6 ....... ...................... 1 2-39 thru 2-40 ................... 0 7-7thru 7-11 .................... 0 * 2-41 thru 2-42 ................... 1 * 7-12 thru 7-14 ................... 1 * 3 -1 .................. .......... 1 * 8 -1 ............................. 1 3-2 thru 3-4 ..................... 0 8-2 thru 8-6 ..................... 0 * 3-5 thru 3-7 ..................... 1 * 8-7 .................. .......... 1 3-8 ............................. 0 8-8 .... .... .............. ... 0 3 -9 ............................. 1 8-8 A ............................ 0 3-10 thru 3-25 ................... 0 8-8B Blank ....... ........ 0 3-26 Blank ...................... 0 8-9 thru 8-10 .................... 0 A Revision 1 MODEL 152 SERIES SERVICE MANUAL Page Revision Page Revision No. No. No. No. * 9 1 ............................. 1 15-14 thru 15-18 ................. 0 9-2 ............................. 0 * 15-19 thru 15-20 ................. 1 * 9-3 ............................. 1 15-20A thru 15-20B .............. 0 9-4 thru 9-7 ..................... 0 * 15-20C thru 15-20D .............. 1 * 9-8 thru 9-9 0 1 * 15-21 ........................... 1 9-10 thru 9-11 ................... 0 15-22 thru 15-24 ................. 0 * 9-12 ............................ 1 * 15-25 thru 15-26 ................. 1 * 10-1 ............................ 1 * 15-26A ......................... 1 10-2 thru 10-10 ................. 0 * 15-26B Blank ................... 1 * 11-1 thru 11-2 ................... 1 15-27 thru 15-30 ................. 0 11-3 thru 11-4 ................... 0 * 16-1 thru 16-2 ................... 1 * 11-5 ...................... ...... 1 16-3 thru 16-6 ................... 0 11-6 ............................ 0 * 16-7 thru 16-8 ................... 1 * 11-6A thru 11-6B ................ 1 * 16-8A .......................... 1 * 1-7 thru 11-8 ................... 1 * 16-8B Blank .................... 1 11-9 thru 11-10 ................. 0 * 16-9 ............................ 1 * 11-10A ......................... 1 16-10 thru 16-18 ................. 0 * 11-10B Blank ................... 1 * 16-19 ........................... 1 * 11-11 .......................... 1 16-20 thru 16-22 ................. 0 11-12thru 11-15 ................ 0 * 16-23 ................... ...... 1 * 11-16 .......................... 1 16-24thru 16-25 ................. 0 * 11-16A ......................... 1 * 16-26thru 16-27 ................. 1 * 11-16B Blank ................... 1 16-28 thru 16-29 ................. 0 11-17 thru 11-19 ................ 0 * 16-30 ................... 1.... .. 1 * 11-20 .......................... 1 16-31thru 16-32 ................. 0 11-21 thru 11-24 ................ 0 * 16-33 thru 16-34 ................. 1 11-24A ......................... 0 * 16-34A ....................... 1 * 11-24B ......................... 1 * 16-34B Blank ................... 1 11-25 ............... 0 16-35 thru 16-36 ................. 0 * 11-26 .......................... 1 16-36A thru 16-36B .............. 0 11-27 thru 11-29 ................ 0 16-37 thru 16-38 ................. 0 * 1i-30 .......................... 1 16-38A ......................... 0 * 11-30A ......................... 1 16-38B Blank ................... 0 * 11-30B Blank ................... 1 16-39 thru 16-46 ................. 0 11-31 thru 11-41 ................ 0 16-46A thru 16-46B .............. 0 11-42 Blank ................... 0 16-47 thru 16-48 ................ 0 12- thru 12-4 .................. 0 16-48A ......................... 0 * 12-5 thru 12-7 ................... 1 16-48B Blank ................... 0 12-8 thru 12-15 ................. 0 16-49 thru 16-51 ................. 0 12-16 Blank .................... 0 * 16-52 .......................... 1 * 13-1 ............................ 1 16-53 thru 16-55 ................. 0 13-2 thru 13-3 ......... 0.......... * 16-56 ........................... 1 134 Blank ..................... 0 16-57 thru 16-59 ................. 0 14-1 thru 14-5 ................... 0 16-60 Blank ..................... 0 14-6 Blank ..................... 0 17-1 thru 17-51 .................. 0 : 15-1 ............................ 1 17-52 Blank ..................... 0 15-2 ............................ 0 * 1 8-1 ............................ 1 15-2A .......................... 0 18-2 thru 18-8 ................... 0 15-2B Blank .................... 0 * 19-1 ............................ 1 15-3 thru 15-11 ................. 0 19-2 thru 19-38 .................. 0 15-12 .......................... 1 19-38A ......................... 0 * 15-12A ......................... 1 19-38B Blank ................... 0 * 15-12B Blank ................... 1 19-39 thru 19-43 ................. 0 * 15-13 .......................... 1 19-44 Blank ..................... 0 Revision 1 B/(C blank) MODEL 152 SERIES SERVICE MANUAL TABLE OF CONTENTS SECTION PAGE NO. Aerofiche/Manual 1. GENERAL DESCRIPTION .......................................... 1A9/1-1 2. GROUND HANDLING, SERVICING, CLEANING, LUBRICATION, AND INSPECTION ............................... 1A15/2-1 3. FUSELAGE ....................................................... 1C18/3-1 4. WINGS AND EMPENNAGE ........................................ 1D22,4-1 5. LANDING GEAR AND BRAKES .................................... E16/5-1 6. AILERON CONTROL SYSTEM ..................................... 1G14/6-1 7. WING FLAP CONTROL SYSTEM ................................... 1H4/7-1 8. ELEVATOR CONTROL SYSTEM ................................... 1H22/8-1 9. ELEVATOR TRIM TAB CONTROL SYSTEM .................. .......... 11139-1 10. RUDDER CONTROL SYSTEM ......... ............................. J7/10-1 11. ENGINE .......................................................... 1J19/11-1 12. FUEL SYSTEM . ................ ............................. 2A2/12-1 13. PROPELLER ...................................................... 2A20/13-1 14. UTILITY SYSTEMS ................................................ 2B5/14-1 15. INSTRUMENTS AND INSTRUMENT SYSTEMS ..................... 2B15/15-1 16. ELECTRICAL SYSTEMS ........................................... 2D9/16-1 17. STRUCTURAL REPAIR ............................................ 2G11/17-1 18. PAINTING ........................................................ 212118-1 19. WIRING DIAGRAMS ............................................... 2J11/19-1 WARNING When performing any inspection or maintenance that requires turning on the master switch, installing a battery, or pulling the propeller through by hand, treat the propeller as if the ignition switch were ON. Do not stand. nor allow anyone else to stand within the arc of the propeller, since a loose or broken wire, or a component malfunction, could cause the propeller to rotate. Revision I MODEL 152 SERIES SERVICE MANUAL CROSS REFERENCE LISTING OF POPULAR NAME VS. MODEL NUMBERS AND SERIALS All aircraft, regardless of manufacturer, are certified under model number degnations. However, popular names are often used for marketing purposes. To provide a consistent method of referring to these aircraft, the model number will be used in this pblication unless the popular name is necessary to differentiate between ver- sions of the same basic model. The following table pro- vide a listing of popular name, model number, and serial number. MODEL SERIAL POPULAR NAME YEAR MODEL BEGINNING ENDING 152 1978 152 15279406 15282031 15211 1979 152 15282032 15283591 1980 152 15283592 15284541 1981 152 15284542 15285161 1982 152 15285162 15285594 1983 152 15285595 15285833 1984 152 15285834 15285939 1985 152 15285940 15286033 REIMS/CESSNA F152 1978 F152 F15201449 F15201528 REIMS/CESSNA F15211 1979 F152 F15201529 F15201673 1980 F152 F15201674 F15201808 1981 F152 F15201809 F15201893 1982 F152 F15201894 F15201928 1983 F152 F15201929 F15201943 1984 F152 F15201944 F15201952 1985 F152 - F15201953 F15201965 1986 F152 F15201966 F15201980 152AEROBAT 1978 A152 A1500433, A1520735 A1520808 1979 A152 681, A1520809 A1520878 1980 A152 A1520879 A1520948 1981 A152 A1520949 A1520983 1982 A152 A1520984 A1521014 1983 A152 A1521015 A1521025 1984 A152 A1521026 A1521027 1985 A152 A1521028 A1521049 REIMS/CESSNA F152 1978 FA152 FA1520337 FA1520347 AEROBAT 1979 FA152 FA1520348 FA1520357 1980 FA152 FA1520358 FA1520372 1981 FA152 FA1520373 FA1520377 1982 FA152 FA1520378 FA1520382 1983 FA152 FA1520383 FA1520387 1984 FA152 NONE 1985 FA152 FA1520388 FA1520415 1986 FA152 FA1520416 FA1520425 ii Revision 1 MODEL 152 SERIES SERVICE MANUAL INTRODUCTION This manual contains factory-recommended procedures and instructions for ground handling, ser- vicing, and maintaining Cessna 152 Series Models. Besides serving as a reference for the exper- ienced mechanic, this manual also covers step-by-step procedures for the less experienced. This service manual is designed for aerofiche presentation. To facilitate the use of the aerofiche, re- fer to the aerofiche header for basic information. KEEPING CESSNA PUBLICATIONS CURRENT The information in this publication is based on data available at the time of publication and is up- dated, supplemented, and automatically amended by all information issued in Service News Let- ters, Service Bulletins, Supplier Service Notices, Publication Changes, Revisions, Reissues and Temporary Revisions. All such amendments become part of and are specifically incorporated within this publication. Users are urged to keep abreast of the latest amendments to this publication through the Cessna Product Support subscription services. Cessna Service Stations have also been supplied with a group of supplier publications which provide disassembly, overhaul, and parts breakdowns for some of the various supplier equipment items. Suppliers publications are updated, supplemented, and specifically amended by supplier issued revisions and service information which may be reissued by Cessna; thereby automatically amending this publication and is communicated to the field through Cessna's Authorized Service Stations and/or through Cessna's subscription ser- vices. WARNING ALL INSPECTION INTERVALS, REPLACEMENT TIME LIMITS, OVERHAUL TIME LIMITS, THE METHOD OF INSPECTION, LIFE LIMITS, CYCLE LIMITS, ETC., RECOMMENDED BY CESSNA ARE SOLELY BASED ON THE USE OF NEW, REMANUFACTURED, OR OVERHAULED CESSNA APPROVED PARTS. IF PARTS ARE DESIGNED, MANUFACTURED, REMANUFACTURED, OVERHAULED, PURCHASED, AND/OR APPROVED BY ENTITIES OTHER THAN CESSNA, THEN THE DATA IN CESSNA'S MAINTENANCE/SERVICE MANUALS AND PARTS CATALOGS ARE NO LONGER APPLICABLE AND THE PURCHASER IS WARNED NOT TO RELY ON SUCH DATA FOR NON-CESSNA PARTS. ALL INSPECTION INTERVALS, REPLACEMENT TIME LIMITS, OVERHAUL TIME LIMITS, THE METHOD OF INSPECTION, LIFE LIMITS, CYCLE LIMITS, ETC., FOR SUCH NON-CESSNA PARTS MUST BE OBTAINED FROM THE MANUFACTURER AND/OR SELLER OF SUCH NON-CESSNA PARTS. 1. REVISIONS/CHANGES. These are issued to the dealers by Cessna Aircraft Company for this publications required, and include only pages that require updating. 2. REISSUE. Manual is reissued to dealers as required, and is a complete manual incorpo- rating all the latest information and outstanding revisions/changes. It supersedes and re- places previous issue(s). REVISIONS/CHANGES and REISSUES can be purchased from a Cessna Service Station or di- rectly from Cessna Parts Distribution (CPD 2), Dept. 701, Cessna Aircraft Company, P. O. Box 949, Wichita, Kansas 67201. All supplemental service information concerning this manual is supplied to all appropriate Cessna Service Stations so that they have the latest authoritative recommendations for servicing these Cessna aircraft. Therefore, it is recommended that Cessna owners utilize the knowledge and exper- ience of the factory-trained Service Station Organization. Revision 1 iii MODEL 152 SERIES SERVICE MANUAL CUSTOMER CARE SUPPLIES AND PUBLICATIONS CATALOG A Customer Care Supplies and Publications Catalog is available from a Cessna Service Station or I directly from Cessna Parts Distribution, Dept. 701, Cessna Aircraft Company, 5800 East Pawnee, Wichita, Kansas 67201. This catalog lists all publications and Customer Care Supplies available from Cessna for prior year models as well as new products. To maintain this catalog in a current status, it is revised quarterly and issued on Aerofiche with the quarterly Service Information Sum- maries. A listing of all available publications is issued periodically by the Cessna Propeller Prod- uct Support Department. SUPPLEMENTAL TYPE CERTIFICATE INSTALLATIONS Inspection, maintenance, and parts requirements for supplemental type certificate (STC) installa- tions are not included in this manual. When an STC installation is incorporated on the airplane, those portions of the airplane affected by the installation must be inspected in accordance with the inspection program published by the owner of the STC. Since STC installations may change sys- tems interface, operating characteristics, and component loads or stresses on adjacent structures, Cessna provided inspection criteria may not be valid for airplanes with STC installations. CUSTOMER COMMENTS ON MANUAL Cessna Aircraft Company has endeavored to furnish you with an accurate, useful, up-to-date man- ual. This manual can be improved with your help. Please use the return card, provided with your manual, to report any errors, discrepancies, and omissions in this manual as well as any general comments you wish to make. iv Revsion 1 MODEL 152 SERIES SERVICE MANUAL SECTION 1 GENERAL DESCRIPTION Page No. TABLE OF CONTENTS Aerofiche/ Manual GENERAL DESCRIPTION ..... A9/1-1 Aircraft Specification ....... 1A9/1-1 Model 152 and F152 ......... IA9/1-1 Stations ................... 1A9/1-1 Description ................ 1A9/1-1 Bolt Torques ............... 1A12/1-4 Model A152 and FA152 ...... 1A9/1-1 Description ................ 1A9/1-1 1-1. GENERAL DESCRIPTION. 1-2. MODEL 152 AND F152 SERIES. 1-3. DESCRIPTION. Cessna Model 152 and F152 Series aircraft described in this manuaL are high-wing monoplanes of all-metal semimonocoque construction They are equipped with fixed tubular spring-steel main gear struts and a steerable nose gear. The nose gear has an air/hydraulic fluid shook strut. Two-place seating is standard, and a double-width, fold-up auxiliary rear seat is optional. Also featured is a "wrap-around" rear window and a swept- back fin and rudder. Powering these aircraft is a four-cylinder. horizontally-opposed. air- cooled Lycoming "Blue Streak" engine, driving an all-metal fixed-pitch propeller. 1-4. MODEL A152 AND FA52 SERIES. 1-5. DESCRIPTION. Aerobat Model A152 and FA152 Series aircraft are a modified version of the current production Model 152. The strucure has been beefed-up" in some areas to meet re- quirements set forth in Acrobatic Category, CAR, Part 3. In addition, quick-relese cabin doors. two-strap shoulder harnesses, and aerbatic paint design are standard Removable seat and back cushions are provided to allow occupants to use either seat-pack or back-pack type parachutes for arobatic maneuvers. The FA152 is powered by a Rolls Royce built, four-cy- linder, horizontally-opposed, air-cooled Lycoming engine. 1-6. AIRCRAFT SPECIFICATIONS. Leading particulars of these aircraft. with dimensions based on gross weight, are given in figure 1-1. If these dimensions are used for constructing a hangar or computing clearances, remember that such factors as nose gear strut inflation. tire pressures, tire sizes and load distribution may result in some dimensions that are considerably different from those listed. 1-7. STATIONS. Station diagrams are shown in figures 1-2 and 1-3 to assist in locating equipment when a written description is inadequate or impractical. Revision 1 1-1 MODEL 152 SERIES SERVICE MANUAL GROSS WEIGHT (Takeoff or Landing) ............................... 1670 Lbs. FUEL CAPACITY Standard Wing (Total) ................... 2......................... 26 GaL Standard Wing (Usable) ............................................ 245 Gal. Long Range Wing (Total) ........................................... 39 GaL Long Range Wing (Usable) .................................... .. 37.5 Gal OIL CAPACITY Without External Filter ............................................. 6 Qt. With External Filter ................................................ 7 Qt. ENGINE MODEL ................................................... Lycoming 0-235 Series PROPELLER (Fixed Pitch) ..................................... ..... 69" McCauley MAIN WHEEL TIRES (Optional) ..................................... 6.00 x 6, 4-Ply Rating Pressure ......................................................... 21 Psi MAIN WHEEL TIRES (Standard) ............................. 15 x 600 x 6, 4-Ply Rating Pressure ......... ...... .................................... 29 Psi NOSE WHEEL Tire (Standard) ....................................... 5.00 x 5, 4-Ply Rating Pressure ..................................................... 30 Psi NOSE GEAR STRUT PRESSURE (Strut Extended) .................. 20 Psi WHEEL ALIGNMENT (Measured With Airplane Empty) Camber ..................... ....................................... 3 to +5 ° Toe-in ................................. ...................... 0" to + .16" AILERON TRAVEL (Prior Serials Thru 15279473, A1520736, F15201428 and FA1520336) Up ............................................................... 20° + 2°.- 0 Down ........................................................ ... .. 14. + 20 -0 AILERON TRAVEL (Beginning Serial 15279474, A1520737, F15201429 and FA1520337) Up .................................................................... 200e 1 ° Down .......................... : .................................... 150° 10 Droop ..... ......................................................... 1° + 1/2 ° Down from Streamlined WING FLAP TRAVEL ................................................ 30° 2 ° Down RUDDER TRAVEL (Parallel to Water Line) Right ............................................................... 20° 30' +0 -2° Left ....... ........................................... ...... .20 30' +0° -2 ° RUDDER TRAVEL (Perpendicular to Hinge Line) Right ................................................................ 23, +00 -20' Left .................................................... ......... 23°, .+0 -2 ELEVATOR TRAVEL Up ................................................................ .. 25 ° 1° Down .............................................................. . 18° + 1° ELEVATOR TRIM TAB TRAVEL Up........................... ...................................... 10 ° 1 Down ............................................................... 20° 1° PRINCIPAL DIMENSIONS Wing Span ........... .......................................... 400.00" Length ..................................... ........................ 284.84" Fin Height (Maximum With Nose Gear Depressed And Flashing Beacon Installed on Fin) ................................. 102.00" Track Width ......................................................... 91.28" Tail Span ........................................................... 120.00" BATTERY LOCATION ............................................... FIREWALL Right Side Figure 1-1. Aircraft Specifications 1-2 MODEL 152 SERIES SERVICE MANUAL 0.00 18.50 56.69 70.69 49.69 Figure 1-2. Fuselage Stations 22.12 31.75 44.12 69.878 Figure 1-3. Wing Stations 95.0~120.00~1-3 138.00 156.00 Figure 1-3. Wing Stations MODEL 152 SERIES SERVICE MANUAL 1-8. BOLT TORQUES. The importance of correct application cannot be overemphasisd. Under- torque can result in unnecesary wear of nuts and bolt. as wall as parts they are holding to- gether. When insuficient pressures are applied, uneven loads will be transmitted through- out assembly, which may result in excesive wear or premature failure due to fatique. Over- torque can be equally damging beause of failure of a bolt or nut from overstrssing threded areas. There are a few simple, but very important, procedure that should be fol- lowed to assure that correct torque is applied a. Calibrate torque wrench periodically to asure accuracy and recheck frequently. b. Be sur that bolt and nut threads are lean and dry unless othrwise specified. o. Run nut down to near contact with washer or bearing surface and check "fiction drag torque required to turn nut. d. Add friction drag torque to desired torque recommended or obtain desired torque as shown in figure 1-4. This is referred to a final torque which should register on Indicator or setting for a snapover-type wrench. e. Apply a smooth even pull when applying torque pressure. If chattering or a jerk- ing motion occurs during final torque, back off and re-torque. f. When instlling a castle nut, start alignment with cotter pin hole at minimum re- commended torque, plus friction drag torque, and do not exceed maimum orplus friction drag. If hole and nut castellation do not align, change washers or nut and try again Exceeding aximum recommnded torque is not reommended unless specifically allowed or recommended for that particulr instllation 1-4 MODEL 152 SERIES SERVICE MANUAL BOLT TORQUE VALUES BOLTS Steel Tension Steel Tension BOLTS Steel Shear AN3 thruAN20 MS20004 thruMS20024 NAS44 AN42 thru AN49 NAS144 thru NAS148 AN73 thru AN81 NAS333 thru NAS340 AN173 thru AN186 NAS585 thru NAS644 MS20033 thru MS20046 NAS624 thru NAS644 MS20073 NAS1303 tru NAS1320 MS20074 NAS172 AN509NK9 NAS174 MS24694 NAS517 AN525NK525 MS27039 Steel Tension NUTS Steel Shear Steel Tension NUTS Steel Shear AN310 AN320 AN310 AN320 AN315 AN364 AN315 AN364 AN363 NAS1022 AN363 NAS1022 AN365 MS 17826 AN365 MS 17826 NAS1021 MS20364 MS17825 MS20364 MS17825 MS20365 MS21045 MS21045 MS20365 NAS1021 MS20500 NAS679 NAS679 NAS1291 FINE THREAD SERIES FINE THREAD SERIES Nut-bolt Torque Limits Torque Limits Nut-bolt Torque Limits Torque Limits size in.-lbs. in.-lbs. size in.-lbs. in.-lbs. . 8-36 12 15 7 9 10-32 25 30 15 20 10-32 20 25 . 12 15 /4-28 80 100 50 60 1/4-28 50 70 30 40 5/16-24 120 145 70 90 5/16-24 100 140 60 85 3/8-24 200 250 120 150 3/8-24 160 190 95 110 7/16-20 520 630 300 400 7/16-20 450 500 270 300 1/2-20 770 950 450 550 1/2-20 480 690 290 410 9/16-18 1100 1300 650 800 9/16-18 800 1000 480 600 5/8-18 1250 1550 750 950 5/8-18 1100 1300 660 780 3/4-16 2650 3200 1600 1900 3/4-16 2300 2500 1300 1500 7/8-14 3550 4350 2100 2600 7/8-14 2500 3000 1500 1800 1-14 4500 5500 2700 3300 1-14 3700 4500 2200 3300 . 1-1/8-12 6000 7300 3600 4400 1-1/8-12 5000 7000 3000 4200 1-1/4-12 11000 13400 6600 8000 1-1/4-12 9000 11000 5400 6600 COARSE THREAD SERIES Nut-bolt Torque Limits Torque Limits COARSE THREAD SERIES NOT USED size in.-lbs. in.-lbs. 8-32 12 15 7 9 10-24 20 25 12 15 1/4-20 40 50 25 30 5/16-18 80 90 48 55 3/8-16 160 185 95 110 7/16-14 235 255 140 155 1/2-13 400 480 240 290 9/16-12 500 700 300 420 5/8-11 700 900 420 540 3/4-10 1150 1600 700 950 7/8-9 2200 3000 1300 1800 1-8 3700 5000 2200 3000 1-1/8-8 5500 6500 3300 4000 11/4-8 6500 8000 4000 5000 Figure 1-4. Torque Values 1-5/(1-6 blank) MODEL 152 SERIES SERVICE MANUAL SECTION 2 GROUND HANDLING, SERVICING, CLEANING LUBRICATION AND INSPECTION WARNING When performing any inspection or maintenacne that re- quires turning on the master switch, installing a battery, or pulling the propeller through by hand, treat the prop- eller as if the ignition switch were ON. Do not stand,nor allow anyone else to stand, within the arc of the propel- ler, since a loose or broken wire, or a component mal- function, could cause the propeller to rotate. Page No. TABLE OF CONTENTS Aerofiche/ Manual GROUND HANDLING ........ 1A16/2-2 Engine Induction Air Filter .. 1B7/2-14 Towing ..................... 1A16/2-2 Vacuum System Filter ...... 1B9/2-16 Hoisting .................... 1A18/2-4 Battery .................... 1B92-16 Jacking .................... 1A19/2-5 Tires ..................... 1B9/2-16 Leveling . .................. 1A1912-5 Nose Gear Shock Strut ...... 1B9/2-16 Parking .................... 1A19/2-5 Nose Gear Shimmy Dampener 1B10/2-17 Tie-Down . .............. 1A19/2-5 Hydraulic Brake System .... 1B10/2-17 Weighing Aircraft ........... 1A19/2-5 CLEANING ................. 1B10/2-17Flyable Storage . .......... A19/2-5 Windshield and Windows .... B11/2-18 ReturningAircraft to Service . 1A20/2-6 Plastic Trim ................ 1B13/2-18B Temporary Storage .......... 1A20/2-6 Painted Surfaces ........... 1B13/2-18B Inspection During Storage .. 1A22/2-7 Aluminum Surfaces ......... 1B13/2-18B Returning Aircraft to Engine and Engine Service . ................. A23,'2-8 Compartment ............. 1B14/2-19 Indefinite Storage ......... 1A23/2-8 Valves and Valve Guides .... 1B15/2-20 Inspection During Storage .. 1A24/2-9 Upholstery andInterior ..... B18/2-21 Returning Aircraft to Propeller .................. 1B18/2-21 Service .................. 1B1/2-10 W heels .................... 1B18/2-21 SERVICING . ................. 1B1/2-10 LUBRICATION ............. B182-21 Fuel .............B1/2-10 Tachometer Drive Shaft ..... 1B19/2-22 Use of Fuel Additives for Wheel Bearings ............ 1B19/2-22 Cold Weather Operations ... 1B1/2-10 Nose Gear Torque Links ..... B19/2-22 Use of Fuel Additives to Wing Flap Actuator ......... 1B19/2-22 Inhibit LeadFouling ....... 1B3/2-12 Rod End Bearings .......... 1B19/2-22 Fuel Drains ................. 1B42-12A INSPECTION REQUIREMENTS 1C6/2-33 Carburetor Drian Plug 100 Hour/Annual ........... 1C6/2-33 Inspection . ..... 5/2-12B Special ................... 1C6/2-33 Carburetor Heat Butterfly Progressive ................ 1C6/2-33Screw Inspection .......... 1B6/2-13 Guide-lines .......... C62-33 Engine Oil ....... ........... 1B6/2-13 Charts ..................... C92-36 Engine Induction Air Filter 1 B7/2-14 Revision 1 2-1 MODEL 152 SERIES SERVICE MANUAL 2-1. GROUND HANDLING. 2-2. TOWING. Moving the aircraft by hand is accomplished by using the wing struts and landing gear struts as push points. A tow bar attached to the nose gear should be used for steering and maneuvering the aircraft on the ground. When no tow bar is available, press down at the horizontal stabilizer front spar adjacent to the fuselage to raise the nose wheel off the ground. With the nose wheel clear of the ground, the aircraft can be turned by pivoting it about the main wheels. Beinning with serials 15285162, A1520984, F1521894 and FA1520378, an optional tow bar stowage installation is available. In the baggage area a bracket located at FS 91.75 and a strap located at FS 70.31 are used to secure and store the tow bar assembly when not in use. Use tow bar carefully to avoid scarring finish on speed fairing. Figure 2-1. Tow Bar CAUTION When towing the aircraft, never turn the nose wheel more than 30 degrees either side of center or the nose gear will be damaged. Do not push on control surfaces or outboard empennage surfaces. When pushing on the tailcone. always apply pressure at a bulkhead to avoid buckling the skin. 2-2 MODEL 152 SERIES SERVICE MANUAL REFER TO SHEET 2 FOR ITEM NUMBERS NOTE Corresponding points on both upper door sills may be used to level the aircraft laterally. Reference points for longitudinal leveling of aircraft are two screws on left side of tailcone. These are indicated in illustration by A. (Also refer to paragraph 2-5) Figure 2-2. Jacking and Leveling (Sheet 1 of 2) 2-3 MODEL 152 SERIES SERVICE MANUAL JACKING INFORMATION ITEM TYPE AND NUMBER REMARS 1 Block 14'4 padded with 1/4" rubber 2 Cessna No. 2-168 Tail TieDown Stand 3 Built-in Jack pad Part of step bracket (SEE CAUTION) 4 No. 2-170 Basic jack (includes Min. closed height: 34" No. 2-71 Slide tube: Liftstroke 22-1/2") Max extension heght: 56-1/2" No. 2-70 Slide tube: Liftstroke 22-1/2" in. closed height: 57-1/2" Max. extension height: 80" No. 2-591 Extension cap AddA 4" No. 2-109 Leg extension Add 12" 1. Wing jacks (4) are placed under front spar of wing just outboard of wing strut, and must extend far enough to raise wheels off ground, and must be of adequate strength. 2. Attach a Cessna 2-168 stand to the tie-down ring. Be sure tail tie-down stand (2) weighs enough to keep tail down under all conditions and that it is strong enough to support any weight that might be placed on it (place shot bags or sand bags on tail stand). In addition, the base of adjustable tail stand is to be filled with concrete for additional weight as a safety factor. 3. Operate jacks evenly until desired height is reached. CAUTION When using built-in jack pad (3), flexibility of the gear strut will cause the main wheel to slide inboard as the wheel is raised, tilting the jack. The jack must be lowered for a second operation. Jacking both wheels simultane- ously at built-in jack pads is not recommended. Jack pad may be used to raise only one main wheel. DO NOT USE brake casting as a jack point. 4. Items (2) and (4) are available from the Cessna Supply Division. Figure 2-2. Jacking and Leveling (Sheet 2 of 2) 2-3. HOISTING. The aircraft may be lifted with a hoist of two-ton capacity by using hoisting rings. which are optional equipment. or by means of suitable slings. The front sling should be hooked to each upper engine mount at the firewall, and the aft sling should be positioned around the fuselage at the first bulkhead forward of the leading edge of the stabilizer. If the 2-4 MODEL 152 SERIES SERVICE MANUAL optional hoisting rings are used, a minimum cable length of 60 inches for each cable is required to prevent bending of the eyebolt-type hoisting rings. If desired, a spreader jig may be fabricated to apply vertical force to the eyebolts. 2-4. JACKING. See figure 2-2 for jacking procedures. 2-5. LEVELING. Corresponding points on both upper door sills may be used to level the aircraft laterally. The reference points for longitudinal leveling of the aircraft are the two screws on the left side of the tailcone. 2-6. PARKING. Parking precautions depend principally on local conditions. As a general precaution, set parking brake or chock the wheels and install the controls lock. In severe weather and high wind conditions, tie down the aircraft as outlined in paragraph 2-7 if a hangar is not available. 2-7. TIE-DOWN. When mooring the aircraft in the open, head into the wind if possible. Secure control surfaces with the internal control lock and set brakes. CAUTION Do not set parking brakes when they are overheated or during cold weather when accumulated moisture may freeze them After completing the preceding, proceed to moor the aircraft as follows: a. Tie ropes, cables, or chains (700 lbs tensile strength) to the wing tie-down fittings located at the upper end of each wing strut. Secure the opposite ends of ropes, cables, or chain to ground anchors. b. Secure a tie-down rope (no chains or cables) to the exposed portion of the engine mount and secure opposite end of rope to a ground anchor. c. Secure the middle of a rope to the tail tie-down ring. Pull each end of rope away at a 45 degree angle and secure to ground anchors at each side of tail d. Secure control lock on pilot control column. If control lock is not available, tie pilot control wheel back with front seat belt. e. These aircraft are equipped with a spring-loaded steering bungee system which affords protection against normal wind gusts. However, if extremely high wind gusts are anticipated, additional external locks may be installed. 2-7A. WEIGHING AIRCRAFT. Refer to Pilot's Operating Handbook. 2-8. FLYABLE STORAGE. Flyable storage is defined as a maximum of 30 days nonoperational storage and/or the first 25 hours of intermittent engine operation. NOTE The aircraft is delivered from Cessna with straight min- eral oi, conforming to Mr-L-6082. This oil should be used for the first 25 hours of engine operation. In the event it is necessary to add oil during the first 25 hours of operation, use only aviation grade straight mineral oil of the recommended viscosity conforming to MIL-6082. 2-5 MODEL 152 SERIES SERVICE MANUAL During the 30 day nonoperational storage or the first 25 hours of intermittent engine operation. every seventh day the propeller shall be rotated through six revolutions, without running the engine. WARNING When rotating engine by hand, always take proper pre- cautions to make sure the engine cannot fire or start when the propeller is moved. If the aircraft is stored outside, tie it down in accordance with paragraph 2-7. In addition. the pitot tube. static air vents, air vents, openings in the enine cowling, and other similar openings shall have protective covers installed to prevent entry of foreign material. After 30 days, aircraft should be flown for 30 minutes or ground run-up until oil has reached operating temperature. (lower green arc range) CAUTION Excessive ground operation shall be avoided. 2-9. RETURNING AIRCRAFT TO SERVICE. After flyable storage, returning the aircraft to service is accomplished by performing a thorough preflight inspection. At the end of the first 25 hours of engine operation drain engine oil and clean oil pressure screen (or change external oil filter element). Service engine with correct grade and quantity of engine oil See figure 2-4 and paragraph 2-21 for correct grade of engine oil 2-10. TEMPORARY STORAGE. Temporary storage is defined as aircraft in a nonoperational status for a maximum of 90 days. The aircraft is constructed of corrosion resistant alclad aluminum, which will last indefinitely under normal conditions if kept clean however. these alloys are subject to oxidation. The first indication of corrosion on unpainted surfaces is in the form of white deposits or spots. On painted surfaces. the paint is discolored or blistered. Storage in a dry hangar is essential to good preservation and should be procured if possible. Varying conditions will alter the measures of preservation, but under normal conditions in a dry hangar, and for storage periods not to exceed 90 days. the following methods of treatment are suggested. NOTE In order to maintain stored airplanes in "new" condition, it is important they be inspected, cleaned, and serviced regu- larly. Routine inspections for overall condition such as cleanliness, damage, corrosion, and water leaks are impera- tive to assure the airplane is being properly maintained. Moisture damage, corrosion, or other damage resulting from neglect while in storage is not covered under the air- plane, engine, or other equipment warranties. a. Fill fuel tanks with correct grade of aviation fuel b. Clean and wax aircraft thoroughly. c. Clean any oil or grease from tires and coat tires with a tire preservative. Cover tires to protect against grease and oil. d. Either block up fuselage to relieve pressure on tires or rotate wheels every 30 days to change supporting points and prevent flat spotting the tires. e. Lubricate all airframe items and seal or cover all openings which could allow moisture and/or dust to enter. 2-6 Revision 1 MODEL 152 SERIES SERVICE MANUAL NOTE The aircraft battery serial number is recorded in the aircraft equipment list. To assure accurate warranty records, the battery should be reinstalled in the same aircraft from which it was removed. If the battery is returned to service in a different aircraft, appropriate record changes must be made and notification sent to Cessna Warranty Administration. Revision I 2-6Ai(2-6B blank) MODEL 152 SERIES SERVICE MANUAL f. Remove battery and store in a cool. dry place: service battery periodically and charge as required. NOTE An engine treated in accordance with the following may be considered protected against normal atmospheric corrosion for a period not to exceed 90 days. g. Disconnect spark plug leads and remove upper and lower spark plugs from each cylinder. NOTE The corrosion preservative oil mixture should conform to MIL-L-6529C Type I heated to 200°F to 220°F spray nozzle temperature. h. Using a portable pressure sprayer. atomize spray preservative oil through the upper spark plug hole in each cylinder with the piston in. a down position. Rotate crankshaft about five revolutions as each cylinder is sprayed. i. After completing step "h." rotate crankshaft so that no piston is at a top position. If the aircraft is to be stored outside. stop two-bladed propeller so that blades are as near horizontal as possible to provide maximum clearance with passing aircraft j. Again spray each cylinder without moving the crankshaft, to thoroughly cover all interior surfaces of the cylinder above the piston. k. Install spark plugs and connect spark plug leads. 1. Apply preservative oil to the engine interior by spraying approximately two ounces of the preservative oil through the oil filler tube. m. Seal all engine openings exposed to the atmosphere. using suitable plugs or non- hygroscopic tape. Attach a red streamer at each point that a plug or tape is installed. n. If the aircraft is to be stored outside, perform the procedures outlined in paragraph 2-7. In addition, the pitot tube, static source vents, air vents, openings in the engine cowling, and other similar openings should have protective covers installed to prevent entry of foreign material o. Attach a warning placard to the propeller with the fullowing notation, "DO NOT TURN PROPELLER--ENGINE PRESERVED--preservation date." 2-11. INSPECTION DURING STORAGE. a. Inspect airframe for corrosion at least once a month and remove dust collections as frequently as possible. Clean and wax aircraft as required. b. Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a month. NOTE Do not move crankshaft when inspecting interior of cylinder for corrosion. c. If at the end of the 90 day period, the aircraft is to be continued in non-operational storage, repeat the procedural steps "g" thru "o" of paragraph 2-10. Revision 1 2-7 MODEL 152 SERIES SERVICE MANUAL 2-12. RETURNING AIRCRAFT TO SERVICE. After temporary storage. use the following procedures to return the aircraft to service. a. Remove aircraft from blocks and check tires for proper inflation. Check for proper nose gear strut inflation. b. Check battery and install. c. Check that oil sump has proper grade and quantity of engine oil d. Service induction air filter and remove warning placard from propeller. e. Remove materials used to cover openings. f. Remove, clean and gap spark plugs. g. While spark plugs are removed. rotate propeller several revolutions to clear excess rust preventive oil from cylinders. h. Install spark plugs and torque to value specified in Section 11 and connect spark plug leads. i. Check fuel strainer. Remove and clean filter screen if necessary. Check fuel tanks and fuel lines for moisture and sediment, drain enough fuel to eliminate moisture and sediment. j. Perform a thorough preflight inspection, then start and warm-up engine. 2-13. INDEFINITE STORAGE. Indefinite storage is defined as aircraft in a nonoperational status for an indefinite period of time. Engines treated in accordance with the following may be con- sidered protected against normal atmosphere corrosion, provided the procedures outlined in paragraph 2-14 are performed at the intervals specified. NOTE In order to maintain stored airplanes in "new" condition, it is important they be inspected, cleaned, and serviced regularly. Routine inspections for overall condition such as cleanliness, damage, corrosion, and water leaks are imperative to assure the airplane is being properly maintained. Moisture damage, corrosion, or other damage resulting from neglect while in storage is not covered under the airplane, engine, or other equipment warranties. a. Operate engine until oil temperature reaches normal operating range. Drain engine oil sump and reinstall drain plug and safety. b. Fill oil sump to normal operating capacity with corrosion-preventive mixture which has been thoroughly mixed. NOTE Corrosion-preventive mixture consists of one part by volume MIL-C-6529C, type I. added to three parts by volume of MIL- L-6082C mineral aircraft engine oil. c. Immediately after filling the oil sump with a corrosion-preventive mixture, fly the air- craft for a period of time not to exceed a maximum of 30 minutes. d. With engine operating at 1200 to 1500 RPM and induction air filter removed, spray corrosion-preventive mixture into induction airbox, at the rate of one-half gallon per minute, until heavy smoke comes from exhaust stack, then increase the spray until en- gine is stopped. CAUTION Injecting corrosion-preventive mixture too fast can cause hy- drostatic lock. 2-8 Revision 1 MODEL 152 SERIES SERVICE MANUAL e. Do not rotate propeller after completing step "d." f. Remove all spark plugs and spray corrosion-preventive mixture, which has been pre- heated to 220°F to 250°F, into all spark plug holes to thoroughly cover interior sur- faces of cylinders. g. Install lower spark plug or install solid plugs, and install dehydrator plugs in the up- per spark plug holes. Be sure that dehydrator plugs are blue in color when installed. h. Cover spark plug lead terminals with shipping plugs (AN4060-1), or other suitable covers. i. With throttle in full open position, place a bag of desiccant in the carburetor intake and seal opening with moisture resistant paper and tape. j. Place a bag of desiccant in the exhaust tailpipe(s) and seal openings with moisture resistant tape. k. Seal cold air inlet to the heater muff with moisture resistant tape. 1. Seal engine breather hose by inserting a protex plug in the breather hose and clamp- ing in place. m. Seal all other engine openings exposed to atmosphere, using suitable plugs or non- hygroscopic tape. n. If the aircraft is to be stored outside, perform the procedures outlined in paragraph 2-7. In addition, the pitot tube, static source vents, air vents, openings in the engine cowling and other similar openings should have protective covers installed to pre- vent entry of foreign material. NOTE Attach a red streamer to each place plugs or bags of desic- cant is placed or moisture resistant tape is installed. Either attach red streamers outside of the sealed area with tape or to the inside of the sealed area with safety wire to prevent wicking of moisture into the sealed area. o. Drain corrosion-preventive mixture from engine sump and reinstall drain plug. NOTE The corrosion-preventive mixture is harmful to paint and should be wiped from painted surfaces immediately. p. Attach a warning placard on the throttle control knob, to the effect that the engine contains no lubricating oil. Attach a warning placard to the propeller with the follow- ing notation, "DO NOT TURN PROPELLER--ENGINE PRESERVED--preservation date." q. Prepare airframe for storage as outlined in paragraph 2-1Oa. thru step "f." NOTE As an alternate method of indefinite storage, the aircraft may be serviced in accordance with paragraph 2-10, provid- ing the aircraft is run-up at maximum intervals of 90 days and then reserviced per paragraph 2-10. 2-14. INSPECTION DURING STORAGE. Aircraft in indefinite storage shall be inspected as follows: a. Inspect cylinder protex plugs each seven days. b. Change protex plugs if their color indicates an unsafe condition. c. If the dehydrator plugs have changed color in one-half of the cylinders, all desiccant material in the engine should be replaced with new material. d. Every six months, respray the cylinder interiors with corrosion-preventive mixture. Revision 1 2-9 MODEL 152 SERIES SERVICE MANUAL NOTE Before spraying, inspect the interior of one cylinder for corro- sion through the spark plug hole and remove at least one rocker box cover and insect the valve mechanism. 2-15. RETURNING AIRCRAFT TO SERVICE. After indefinite storage, use the following procedure to return the aircraft to service. a. Remove aircraft from blocks and check tires for correct inflation. Check for correct nose gear strut inflation. b. Check battery and install. c. Remove all paper, tape, desiccant bags, and streamers used to seal and cover openings. d. Remove warning placards posted at throttle and propeller. e. Remove and clean engine oil screen, then reinstall and safety. On aircraft that are equipped with an external oil filter, install new filter element. f. Remove oil sump drain plug (or open quick drain valve) and drain oil sump. Install and safety drain plug (or close quick drain valve) and service engine with correct amount and grade of oil per figure 2-4. NOTE The corrosion-preventive mixture will mix with the engine lubricating oil, so flushing the oil system is not necessary. Draining the oil sump wilt remove enough of the corrosion- preventive mixture. NOTE The corrosion-preventive mixture is harmful to paint and should be wiped from painted surfaces immediately. g. Service and install the induction air filter. h. Remove dehydrator plugs and spark plugs or plugs installed in spark plug holes and ro- tate propeller several revolutions to clear corrosion-preventive mixture from cylinders. i. Clean, gap, and install spark plugs. Torque spark plugs to value listed in Section 11. j. Check fuel strainer. Remove and clean filter screen. Check fuel tanks and fuel lines for | moisture and sediment, and drain enough fuel to eliminate moisture and sediment. k. Perform a thorough preflight inspection, then start and warm-up engine. | 1. Thoroughly clean and visually inspect aircraft and flight test aircraft. 2-16. SERVICING. 2-17. Servicing requirements are shown in figure 2-4. The following paragraphs supplement this figure by adding details not included in the figure. 2-18. FUEL. Fuel tanks should be filled immediately after flight to lessen moisture condensation. Tank capacities are listed in Section 1. The recommended fuel grade to be used is given in fig- ure 2-4. WARNING Do not fly with contaminated or unapproved fuel. 2-18A. USE OF FUEL ADDITIVES FOR COLD WEATHER OPERATION. Strict adherence to rec- ommended preflight draining instructions will eliminate any free water accumulations from the tank sumps. While small amounts of water may still remain in solution in the gasoline, it will normally be consumed and go unnoticed in the operation of the engine. 2-10 Revision 1 MODEL 152 SERIES SERVICE MANUAL One exception to this can be encountered when operating under the combined effect of: (1) use of certain fuels, with (2) high humidity conditions on the ground (3) followed by flight at high altitude and low temperature. Under these unusual conditions small amounts of water in solution can precipitate from the fuel stream and freeze in sufficient quantities to induce partial icing of the engine fuel system. While these conditions are quite rare and will not normally pose a problem to owners and operators, they do exist in certain areas of the world and consequently must be dealt with, when encountered. Therefore, to alleviate the possibility of fuel icing occurring under these unusual conditions it is permissible to add isopropyl alcohol or ethylene glycol monomethyl ether (EGME) compound to the fuel supply. See Figure 2-2A for fuel additive mixing ratio. The introduction of alcohol orEGME compound into the fuel provides two distinct effects: (1) it absorbs the dissolved water from the gasoline and (2) alcohol has a freezing temperature depressant effect. Alcohol, if used, is to be blended with the fuel in a concentration of 1% by volume. Concentrations greater than 1% are not recommended since they can be detrimental to fuel tank materials. The manner in which the alcohol is added to the fuel is significant because alcohol is most effective when it is completely dissolved in the fuel. To insure proper mixing the following is recommended: 1. For best results the alcohol should be added during the fueling operation by pouring the alcohol directly on the fuel stream issuing from the fueling nozzle. 2. An alternate method that may be used is to premix the complete alcohol dosage with some fuel in a.separate clean container (approximately 2-3 gallon capacity) and then transfer this mixture to the tank prior to the fuel operation. Any high quality isopropyl alcohol may be used, such as: Anti-icing fluid (MILF-5566) or Isopropyl alcohol (Federal Specification TT-I-735a). Ethylene glycol monomethyl ether (EGME) compound in compliance with MIL-I-27686 or Phillips PFA-55MB, if used, must be carefully mixed with the fuel in concentrations not to exceed 0.15% by volume. CAUTION Mixing of the EGME compound with the fuel is extremely important because concentration in excess of that recom- mended (0.15 percent by volume maximum) will result in detrimental affects to the fuel tanks, such as deterioration of protective primer and sealants and damage to O-rings and seals in the fuel system and engine components. Use only blending equipment that is recommended by the manufacturer to obtain proper proportioning. Do not allow the concentrated EGME compound to come in contact with the airplane finish or fuel cell as damage can result. 2-11 MODEL 152 SERIES SERVICE MANUAL Prolonged storage of the airplane will result in a water build-up in the fuel which "leeches out" the additive. An indication of this is when an excessive amount of water accumulates in the fuel tank sumps. The concentration can be checked using a differential refractometer. It is imperative that the technical manual for the differential refractometer be followed explicitly when checking the additive concentration. 18 4.5 140 0 10 20 30 40 50 60 70 80 90 100 110 characteristics of the Lycoming 0-235 engine indicate that use of 100 Low Lead fuel signifi- cantly improves spark plug life and reduces spark plug cleaning requirements due to lead fouling. Alcor, Inc. markets TCP (Tri-cresyl-phosphate) as a fuel additive used as a lead in- hibitor fornon-turbocharged Lycoming engines. Fuel system components in Cessna aircraft exhibit no detrimental effects from use of TCP when mixed with aviation fuel in accordance with blending table shown in Figure 2-2B. 2-12 Revision 1 MODEL 152 SERIES SERVICE MANUAL GASOLINE CORRECT AMOUNT OF ALCOR TCP CONCENTRATE QUANTITY 2ML/TEL/GAL 4ML/TEL/GAL TO BE TREATED 100 LL GRADE 100/130 GRADE TREATED U.S. LIQUID CC OR LIQUID CC IR GALLONS OUNCES ML OUNCES ML 5 0.5 15 1.1 31 10 1.0 31 2.1 63 15 1.6 45 3.2 94 20 2.1 61 4.2 126 25 2.6 76 5.3 157 30 3.1 92 6.4 188 35 3.6 107 7.4 220 40 4.1 122 8.5 251 45 4.7 138 9.6 282 50 5.2 153 10.6 314 100 10.5 306 21.2 628 155 1 PT. 473 1 QT. 975 310 1 QT. 946 2 QTS. 1950 500 3.2 PTS. 1530 3.3 QTS 3140 600 1 GAL. 3785 1200 1240 1 GAL. 3785 -- Figure 2-2B. TCP Blending Table For Aviation Gasoline 2-19. FUEL DRAINS. Fuel drains are located in the fuel tanks, fuel line drain tee, fuel strainer and carburetor. The fuel tanks and fuel strainer have drain valves. To activate the tank drain valve and fuel line drain tee for fuel sampling, place cup up to valve and depress valve with rod protruding from cup. See Section 12 for illustration of fuel tank drain valve. The strainer valve is an integral part of the fuel strainer assembly. The strainer drain is equipped with a control which is located adjacent to the oil dipstick. Access to the control is through the oil dipstick access door. Open drains and remove drain cap at intervals specified in figure 2-4. Also, during daily inspection of the fuel strainer, fuel line drain tee and tanks, if water is found in the system, all fuel drains should be temporarily opened and all water drained from the system. If the aircraft has been serviced with improper fuel grade, defuel completely, and refuel with correct grade. Provided weight and balance considerations will permit, fuel tanks should be kept full between flights. Revision 12-12A MODEL 152 SERIES SERVICE MANUAL NOTE If fuel tank quick-drains are not installed, at least one quart of fuel should be drained from the fuel strainer with the selector valve in a position to assure each tank is drain- ing fuel. 2-20. CARBURETOR DRAIN PLUG INSPECTION. In order to prevent the possibility of thread sealant contamination in the carburetor float chamber. cleaning and inspection of the carburetor should be accomplished at each 100-hour inspection and anytime water in the fuel is suspected. a. With the fuel valve OFF. remove carburetor drain plug and clean off any sealant present on the end of the plug or in the threads on the plug. b. Inspect drain plug hole in the carburetor and remove any sealant remaining in the hole. c. Turn fuel valve to ON to flush float chamber and drain plug chamber while probing drain plug hole to ascertain that all residue of sealant material is dislodged and washed out of the chamber. Flushing operation should last 15 to 30 seconds. d. A second flushing should then be accomplished and the drained fuel retained for inspection to ensure that no sealant particles are present e. Install drain plug as follows: 1. Install drain plug in carburetor 1-1/2 to 2 turns. 2. Apply sealant to drain plug threads (use NS-40 (RAS-4) or equivalent). 3. Tighten and safety drain plug. f. Turn fuel valve ON and inspect for evidence of fuel leakage. 2-128 Revision I MODEL 152 SERIES SERVICE MANUAL 2-20A. CARBURETOR HEAT BUTTERFLY SCREW INSPECTION. The two screws attaching the carburetor heat to its shaft on the aircraft listed below must be checked for (and tight- ened, if loose) as a part of every 100-hour or annual inspection. a. Affected aircraft serials numbers: 15279406 thru 15282096, A1520735 thru A1520810, F15201429 thru F15201638, and FA1520337 thru FA1520351. 2-21. ENGINE OIL. Check engine lubricating oil with the dipstick five to ten minutes after the engine has been stopped. The aircraft should be in as near a level position as possible when checking the engine oil, that a true reading is obtained. Engine oil should be drained while the engine is still hot, and the nose of the aircraft should be raised slightly for more positive draining of any sludge which may have collected in the engine oil sump. Engine oil should be changed as specified in servicing intervals figure 2-4. Reduce these intervals for pro- longed operations in dusty areas, in cold climates where sludging conditions exist, or where short flights and long idle periods are encountered. Always change oil and oil filter (or clean pressure screen) whenever oil appears dirty on dipstick. Aviation grade oil conforming to AVCO Lycoming Service Instruction No. 1014, and any revisions or supplements thereto, shall be used in the "Blue Streak" (Lycoming) engine. NOTE New or newly-overhauled engines should be operated on aviation grade straight mineral oil until the first oil change. If an ashless dispersant oil is used in a new or newly-overhauled engine, high oil consumption may be ex- perienced. The anti-friction additives in detergent and dispersant oils will retard "break-in" of the pistons, rings and cylinder walls. This condition can be avoided by the use of straight mineral oil. If oil must be added during the first 25 hours, us only aviation grade straight mineral oil (non- detergent) conforming to MIL-L-6082. After the first 25 hours of operation, drain engine oil sump and clean the oil pressure screen. If an external oil filter is installed, change the oil filter. Refill sump with straight mineral oil and use until a total of 50 hours have accumulated or oil consump- tion has stabilized, then change to ashless dispersant oil. NOTE Engine oil contamination increases possibility of sticking and/or stuck valves. More frequent oil and filter changes (5l0-houri will minimize accumulation of harmful contami- nants. When the aircraft cannot be flown frequently, the oil and filter should be changed souner than 50-hour interval. Change oil and filter every 25 hours to eliminate moisture and acids that collect in oil of an inactive engine. NOTE Phillips X/C II-Aviation Multi-viscosity oil has not been ap- proved for use by AVCO Lycoming and should not be used in Cessna airplanes. Revision 12-13 MODEL 152 SERIES SERVICE MANUAL Valve shown open. To close, twist screwdriver until valve unlocks and snaps down to closed position. Figure 2-3. Quick-Drain Valve An oil quick-drain valve may be installed. This valve provides a quicker and cleaner method of draining the engine oil This valve is installed in the oil drain port of the oil sump and allows oil to be drained by attaching a hose over the fitting end and pushing up. causing the oil to drain through the hose into a container. To drain the engine oil proceed as follow a. Operate engine until oil temperature is at normal operating temperature. b. (With Quick-Drain Valve.) Attach a hose to the quick-drain valve in the oil sump. Push up on quick-drain valve until it locks open. and allow oil to drain through hose into container. c. (Without Quick-Drain Valve.) Remove oil drain plug from engine sump and allow oil to drain into a container. d. After engine oil has drained. close quick-drain valve as shown in figure 2-3 and remove hose, or install and safety drain plug. e. Service engine with correct quantity and grade of engine oil in accordance with figure 2-4. 2-22. ENGINE INDUCTION AIR FILTER. The induction air filter keeps dust and dirt from en- tering the induction system. The value of maintaining the air filter in a good clean condi- tion can never be overstressed. More engine wear is caused through the use of a dirty or damaged air filter than is generally believed. Engine oil contamination increases possibil- ity of sticking valves, and operating engine with a clean air filter also keeps dirt from accu- mulating in oil supply. The frequency with which the filter should be removed, inspected, and cleaned will be determined primarily by aircraft operating conditions. A good general rule, however, is to remove, inspect, and clean the filter at least every 100 hours of engine operating time and more frequently if warranted by operating conditions. Some operators prefer to hold spare induction air filters at their home base of operation so that a clean filer is always readily available for use. Under extremely dusty conditions, daily servicing of the filter is recommended. To service the filter, proceed as follows: a. Remove filter from aircraft. 2-14 Revision 1 MODEL 152 SERIES SERVICE MANUAL NOTE Use care to prevent damage to filter element when cleaning filter with compressed air. b. Clean filter by blowing with compressed air (not over 100 psi) from direction opposite of normal air flow. Arrows on filter case indicate direction of normal air flow. CAUTION Do not use solvent or cleaning fluids to wash filter. Use only a water and household detergent solution when washing the filter. c. After cleaning as outlined in step "b", the filter may be washed, if necessary, in a solution of warm water and a mild household detergent. A cold water solution may be used. NOTE The filter assembly may be cleaned with compressed air a maximum of 30 times or it may be washed a maximum of 20 times. A new filter should be installed after 500 hours of engine operating time or one year, whichever should occur first. However, a new filter should be installed at anytime the existing filter is damaged. A damaged filter may have sharp or broken edges in the filtering panels which would allow unfiltered air to enter the induction system. Any filter that appears doubtful, shall have a new filter installed in its place. d. After washing, rinse filter with clear water until rinse water draining from filter is clear. Allow water to drain from filter and dry with compressed air (not over 100 psi). NOTE The filtering panels of the filter may become distorted when wet, but they will return to their original shape when dry. e. Be sure that the air box is clean, inspect filter. If filter is damaged, install a new filter. f. Install filter at entrance to air box with gasket on aft face of filter frame and pointed in the correct direction. 2-15 MODEL 152 SERIES SERVICE MANUAL 2-23. VACUUM SYSTEM FILTER. The vacuum system central air filter keeps dirt and dust from entering the vacuum operated instruments. Inspect filter element every 200 hours of operat- ing time for damage. Change central air filter element every 500 hours of operating time and whenever it becomes sufficiently clogged to cause suction gage readings to drop below 4.6 inches of mercury. Also, do not operate the vacuum system with the filter removed, or a vacuum line disconnected as particlesof dust or other foreign matter may enter the system and damage the vacuum operated instruments. CAUTION Excessive smoking will cause premature filter clogging. 2-24. BATTERY. Servicing the 24-volt battery involves adding distilled water to maintain the elec- trolyte level no higher than bottom of split ring indicator and no lower than top of separators (approximately 1/8-inch below split ring) within filler holes, checking the battery cable con- nections, and neutralizing and cleaning spilled electrolyte or corrosion. Use bicarbonate of so- da (baking soda) and water to neutralize electrolyte or corrosion. Follow with a thorough flushing with water. Brighten cables and terminals with a wire brush, then coat with petro- leum jelly before connecting. The battery box also should be checked and cleaned if any corro- sion is noted. Distilled water, not acid or "rejuvenators," should be used to maintain electro- lyte level. Check the battery every 100 hours (or at least every 30 days), more often in hot weather. See Section 16 for detailed battery removal, installation, and testing instructions. 2-25. TIRES. Maintain tire pressure at the airpressures specified in figure 1-1. When checking tire pressure, examine tires for wear. cuts. bruises, and slippage. Remove oil grease. and mud from tires with soap and water. NOTE Recommended tire pressures should be maintained. Especially in cold weather. remember that any drop in temperature of the air inside a tire causes a correspond- ing drop in air pressure. 2-26. NOSE GEAR SHOCK STRUT. The nose gear shock strut requires periodic checking to ensure that the strut is filled with hydraulic fluid and is inflated to the correct air pressure. To service the nose gear shock strut, proceed as follows: a. Remove valve cap and release all air. b. Remove valve housing assembly. c. Compress strut completely (stops in contact with outer barrel hub). d. Oil level. (1) Fluid used should comply with specification MIL-H-5606. (2) Fill strut to bottom of valve installation hole. (3) Maintain oil level at bottom of valve installation hole. e. Fully extend strut. f. Replace valve housing assembly. g. With strut fully extended and nose wheel clear of ground, inflate strut to 20 PSI. 2-16 Revision I MODEL 152 SERIES SERVICE MANUAL NOTE The nose landing gear shock strut will normally require only a minimum amount of service. Maintain the strut extension pressure, as shown in figure 1-1. Lubricate landing gear as shown in figure 2-5. Check landing gear daily for general cleanliness, security of mounting, and for hydraulic fluid leakage. Keep machined surfaces wiped free of dirt and dust, using a clean lint-free cloth saturated with MIL-H-5606 hydraulic fluid or kerosene. All surfaces should be wiped free of excessive hydraulic fluid. 2-27. NOSE GEAR SHIMMY DAMPENER. The shimmy dampener should be serviced at least every 50 hours. The shimmy dampener must be filled completely with fluid, free of entrapped air, to serve its purpose. To service the shimmy dampener, proceed as follows: a. Remove shimmy dampener from aircraft. b. While holding the dampener in a vertical position with fitting end pointed downward. pull fitting end of the dampener shaft to its limit of travel. c. While holding dampener in this position, fill dampener through open end of cylinder with hydraulic fluid. d. Push the shaft upward slowly to seal off the filler hole. e. Clean dampener with solvent. Be sure to keep the shaft protruding through the filler hole until dampener is installed on the aircraft. f. Install dampener on aircraft. NOTE Keep shimmy dampener, especially the exposed portions of the dampener piston shaft, clean to prevent collection of dust and grit which could cut the seals in the dampener barrel. Keep machined surfaces wiped free of dirt and dust, using a clean lint-free cloth saturated with MIT-H- 5606 hydraulic fluid or kerosene. All surfaces should be wiped free of excessive hydraulic fluid. 2-28. HYDRAULIC BRAKE SYSTEM. Check brake master cylinders and refill with hydraulic fluid as specified in the inspection charts. Bleed the brake system of entrapped airwhenever there is a spongy response to the brake pedals. Refer to Section 5 for filling and bleeding of the brakes. 2-29. CLEANING. 2-30. Keeping the aircraft clean is important. Besides maintaining the trim appearance of the aircraft, cleaning lessens the possiblity of corrosion and makes inspection and maintenance easier. 2-17 MODEL 152 SERIES SERVICE MANUAL 2-31. CLEANING AND CARE OF THE WINDSHEILD AND WINDOW. a. General Maintnanoe Procedures. The following procedures provide information re- garding cleaning and servicing windshields and windows. Improper cleaning, or use of unapproved cleaning agents can cause damage to windshield and windows. b. Materials Required: NAME MANUFACTURER USE Mild soap or detergent Commercially available Cleaning windshields and (hand dishwashing type) windows. Aliphatic Naphtha Type II Commercially available Removing deposits which conforming to Federal cannot be removed with Specification TT-N-95 mild soap solution. Polishing wax: S.C. Johnson and Son, Inc. Waxing acrylic wind- (Refer to Note 1) shields and windows. Turtle Wax (paste) Turtle Wax, Inc. Chicago, IL 60638 Great Reflections El. duPont deNemours Paste Wax and Co. (Inc) Wilmington, DE 19898 Slip-stream Wax Classic Chemical (paste) Grand Prairie, TX 75050 Acrylic polish conforming Permatex Company, Inc. Cleaning and polishing to Federal Specification Kansas City, KS 66115 acrylic windshields and P-P-560 such as: windows. Permatex plastic cleaner Number 403D Soft cloth, such as: Commercially available Applying and removing wax Cotton flannel or old and polish. tee shirt material c. Cleaning Instructions. CAUTION Windshields and windows (Acrylic Faced) are easily dam- aged by improper handling and cleaning techniques. 1. Place airplane inside hangar or in shaded area and allow to cool from heat of sun's direct rays. 2. Using clean (preferably running) water, flood the surface. Use bare hands with no jewelry to feel and dislodge any dirt or abrasive materials. 3. Using a mild soap or detergent (such as a dishwashing liquid) in water, wash the surface. Again use only the bare hand to provide rubbing force. (A clean cloth may be used to transfer the soap solution to the surface, but extreme care must be exercised to prevent scratching the surface.) 2-18 MODEL 152 SERIES SERVICE MANUAL 4. On acrylic windshields and windows only, if soils which cannot be removed by a mild detergent remain, Type II aliphatic naphtha applied with a soft clean cloth may be used as a cleaning solvent. Be sure to frequently refold cloth to avoid rede- positing soil and/or scratching windshield with any abrasive particles. 5. Rinse surface thoroughly with clean fresh water and dry with a clean cloth. Do not rub plastic with a dry cloth as this builds up an electrostatic charge which at- tracts dust. CAUTION Do not use any of the following on or for cleaning wind- shields and windows: methanol, denatured alcohol, gaso- line, benzene, xylene, MEK, acetone, carbon tetrachloride, fire extinguisher fluid, de-icer fluid, lac- quer thinners, commercial or household glass window cleaning sprays. 6. Hard polishing wax should be applied to acrylic surfaces. (The wax has an index of refractionnearly the same as transparent acrylic and will tend to mask any shallow scratches on the windshield surface). 7. Acrylic surfaces may be polished using a polish meeting Federal Specification P- P-560 applied per the manufacturer's instructions. NOTE When applying and removing wax and polish, use a clean soft cloth such as well worn tee shirt material or cotton flannel 8. DO NOT USE rain repellent on acrylic surfaces. d. Windshield and Window Preventive Maintenance. NOTE Utilization of the following techniques will help minimize windshield and window crazing. 1. Keep all surfaces of windshields and windows clean. 2. If desired, wax acrylic surfaces. 3. Do not park or store airplane where it might be subjected to direct contact with or vapors from: methanol, denatured alcohol, gasoline, benzene, xylene, MEK. acetone, carbon tetrachloride, lacquer thinners, commercial or household window cleaning sprays, paint strippers, or other types of solvents. 4. Do not use solar screens or shields installed on inside of airplane or leave sun vis- ors up against windshield. The reflected heat from these items causes elevated temperatures which accelerate crazing and may cause formation of bubbles in the inner ply of multiple ply windshields. 5. Do not use a canvas cover on the windshield or windows unless freezing rain or sleet is anticipated since the cover may scratch the plastic surface. Revision I 2-18A MODEL 152 SERIES SERVICE MANUAL 2-32. PLASTIC TRIM. The instrument panel, plastic trim, and control knobs need only. be wiped with a damp cloth. Oil and grease on the control wheel and control knobs can be removed with a cloth moistened with Stoddard solvent. Volatile solvents, such as mentioned in paragraph 2-32, must never be used since they soften and craze the plastic. 2-33. PAINTED SURFACES.The painted exterior surfaces of your new Cessna have a durable, long lasting finish Approximately 10 days are required for the paint to cure completely; in most cases, the curing period will have been completed prior to delivery of the airplane. In the event that polishing or buying is required within the curing period, it is recommended that the work be done by someone experienced in handling uncured paint. Any Cessna Dealer can accomplish this work. Generally, the painted surfaces can be kept bright by washing with water and mild soap, fol- lowed by a rinse with water and drying with cloths or a chamois. Harsh or abrasive soaps or detergents which cause corrosion or scratches should never be used. Remove stubborn oil and grease with a cloth moistened with Stoddard solvent. To seal any minor surface chips or scratches and protect against corrosion, the airplane should be waxed regularly with a good automotive wax applied in accordance with the man- ufacturer's instructions. If the airplane is operated in a seacoast or other salt water environ- ment, it must be washed and waxed more frequently to assure adequate protection Special care should be taken to seal around rivet heads and skin laps, which are the areas most sus- ceptible to corrosion. A heavier coating of wax on the leading edges of the wings and tail and on the cowl nose cap and propeller spinner will help reduce the abrasion encountered in these areas. Reapplication of wax will generally be necessary after cleaning with soap solu- tions or after chemical de-icing operations. 2-34. ALUMINUM SURFACES. The aluminum surfaces require a minimum of care, but should never be neglected. The aircraft may be washed with clean water to remove dirt and may be washed with nonalkaline grease solvents to remove oil and/or grease. Household type detergent soap powders are effective cleaners, but should be used cautiously since some of them are strongly alkaline. Many good aluminum cleaners, polishes and waxes are available from commercial suppliers of aircraft products. 2-18B MODEL 152 SERIES SERVICE MANUAL 2-35 ENGINE AND ENGINE CO ARTMENT. An engine and accessories wash-down should be accomplished during each 100-hour inspection to remove oil, grease, salt corrosion or other residue that might conceal component defects during inspction. Also, periodic cleaning can be very effective in preventive mantenance. Precautions should be taken when working with cleaning agents such as wearing of rubber gloves, an apron or coveralls and a face shield or goggles. Use the least toxic of available cleaning agents that will satisfactorily accomplish the work. These cleaning agents include: (1) Stoddard Solvent (Specification P-D-680 type II (2) A water alkaline detergent cleaner (MILC-25769J) mixed, 1 part cleaner, 2 to 3 parts water and 8 to 12 parts Stoddard solvent or (3) A solvent base emulsion cleaner (MIL-C-4361B) mixed 1 part cleaner and 3 parts Stod- dard solvent. CAUTION Do not use gasoline or other highly flammable sub- stances for wash down. Perform all cleaning operations in well ventilated work areas and ensure that adequate fire- fighting and safety equipment is available. Do not smoke or expose a flame, within 100 feet of the cleaning area Compressed air, used for cleanig agent, application or drying , should be regulated to the lowest practical pressure. Use of a stiff bristle brush rather than a steel brush is recommended if cleaningagents do not remove excess grease and grime during spraying. A recommended procedure for cleaning an engine and accessories is as follows: CAUTION Do not attempt to wash an engine which is still hot or running. Allow the engine to cool before cleaning a Remove engine cowling. b. Carefully cover the coupling area between the vacuum pump and the engine drive shaft so that no cleaning solvent can reach the coupling or seal c. Cover the open end of the vacuum discharge tube. d. Cover the vacuum relief valve filter, if installed in the engine compartment. e. Use fresh water for wash-down when the engine is contaminated with salt or cor- rosive chemicals. A cleaning agent such as described previously may then be used to remove oil and grime. CAUTION Care should be exercised to not direct cleaning agents or water streams at openings on the starter, magnetos, al- ternator or vacuum pump. f. Thoroughly rinse with clean warm water to remove all traces of cleaning agents. 2-19 MODEL 152 SERIES SERVICE MANUAL CAUTION Cleaning agents should never be left on engine compo- nants for an extended period of time. Failure to remove them may causedamage to components such as neoprene seals and silicone fire sleeves, and could cause additional corrosion. g. Completely dry engine and accessories using clean dry compressed air. h. Remove the coverover the coupling area. i. Remove the cover from the vacuum dischargetube. j. Remove the cover from the vacuum relief valve filter, if installed. k. If desired, engine cowling may be washed with the same cleaning agents, then rinsed thoroughly and wiped dry. After cleaning engine, relubricateall control arms and moving parts as required. L Reinstallengine cowling. WARNING For maximum safety, check that the magneto switches are OFF, the throttle is closed. the mixture control is in the idle cut-off position and the airplane is secured be fore rotating the propeller by hand. Do not stand within the arc of the propeller blades while turning the propel- lar. m. Before startingengine, rotate the propeller by hand no less thanfour complete revolution. CAUTION Particular care should be given to electrical equipment be- fore cleaning. Solvent should not be allowed to enter magne- tos, starter, alternator, voltage regulator, and the like. Hence, these components should be protected before saturat- ing the en gine with solvent. Any fuel, oil, and air openings should be covered before washing the e ngine with solvent. Caustic cleaning solutions should not be used. After clean- ing engine, relubricate all control arms and moving parts. 2-35A. VALVES AND VALVE GUIDES. Operating with any of the following conditions present can promote deposit build-up reducing valve guide clearance and resulting in valve stick- ing: a. Contaminated, dirty engine oil supply. b. High ambient temperatures. c. Slow flight with reduced cooling. d. High lead content of fuel. If any of the above is present or valve hesitation or engine missing is observed, then inspec- tion and cleaning is recommended. Field experience has shown that valve guide cleaning is beneficial for reducing valve sticking when accomplished every 500 to 1000 hours, depend- ing on individual engine operating conditions. (Refer to Lycoming Service Instruction 1425 for suggested maintenance procedures). 2-20 Revision 1 MODEL 152 SERIES SERVICE MANUAL 2-36. UPHOLSTERY AND INTERIOR. Keeping the upholstery and interior trim clean prolongs upholstery fabric and interior trim life. To clean the interior, proceed as follows a. Empty all ash trays and refuse containers. b. Brush or vacuum clean the upholstery and carpet to remove dust and dirt. c. Wipe leather and plastic trim with a damp cloth. d. Soiled upholstery fabrics and carpet may be cleaned with a foam-type detergent used according to manufacturer's instructions. e. Oil spots and stains may be cleaned with household spot removers, used sparingly. Before using any solvent, read the instructions on the container and test it on an obscure place in the fabric to be cleaned. Never saturate the fabric with volatile solvent: it may damage the padding and backing material. NOTE Repair kits are available for the repair of cracks in ABS, PBC, PVCP, graphite and fiberglass material. (Contact a Cessna Service Station for information or to order. 2-37. PROPELLER. Wash hub and blade with a soft cloth and Stoddard cleaning solvent or equivalent, then dry thoroughly with compressed air. The propeller should be wiped occasionally with an oily cloth, then wiped with a dry cloth. In salt water areas this will assist in corrosion proofing the propeller. 2-38. WHEELS. The wheels should be washed periodically and examined for corrosion, chipped paint, and cracks or dents in the wheel halves or in the flanges or hubs. If defects are found. remove and repair in accordance with Section 5. Discard cracked wheel halves, flanges or hubs and install new parts. 2-39. LUBRICATION. 2-40. Lubrication requirements are shown in figure 2-5. Before adding grease to grease fittings. wipe dirt from fitting. Lubricate until grease appears around parts being lubricated. and wipe excess grease from parts. The following paragraphs supplement figure 2-5 by adding details. Revision 1 2-21 MODEL 152 SERIES SERVICE MANUAL 2-41. TACHOMETER DRIVE SHAFT. Refer to Section 15. 2-42. WHEEL BEARINGS. Clean and repack the wheel bearings at the first 100-hour inspection and at each 500-hour inspection thereafter. If more than the usual number of takeoffs and landings are made, extensive taxiing is required, or the aircraft is operated in dusty areas or under seacoast conditions, cleaning and lubrication of the wheel bearings shall be accomp- lished at each 100-hour inspection. 2-43. NOSE GEAR TORQUE LINKS. Lubricate nose gear torque links every 50 hours. When operating in dusty conditions, more frequent lubrication is required. 2-44. WING FLAP ACTUATOR. Clean and lubricate wing flap actuator jack screw each 100 hours as follows: a. Expose jack screw by operating flaps to full down position. b. Clean jack screw threads with solvent rag and dry with compressed air. NOTE It is not necessary to remove actuator from aircraft to clean or lubricate threads. c. With oil can, apply light coat of No. 10 weight nondetergent oil-to threads of jack screw. 2-45. ROD END BEARINGS. Periodic inspection and lubrication is required to prevent corrosion of the bearing in the rod end. At each 100-hour inspection, disconnect the control rods at the aileron flap and nose gear steering tubes. and inspect each rod end for corrosion. If no corrosion is found, wipe the surface of the rod end balls with general purpose oil and rotate ball freely to distribute the oil over its entire surface and connect the control rods to their respective units. If corrosion is detected during the inspection, install new rod ends. 2-22 MODEL 152 SERIES SERVICE MANUAL HYDRAULIC FLUID: SPEC. NO. MIL-H-5606 SPECIFIED AVIATION GRADE FUELS: WARNING ONLY AVIATION GRADE FUELS ARE APPROVED FOR USE. ENGINE MODEL APPROVED FUEL GRADES NOTES LYCOMING 0-235-L2C 100LL (blue) or 100 (green) (formerly 100/130) 1, 2, 3 LYCOMING 0-235-N2C 100LL (blue) or 100 (green) (formerly 100/130) 1, 2,3 Figure 2-4. Servicing (Sheet 1 of 5) Revision 1 2-23 MODEL 152 SERIES SERVICE MANUAL NOTES 1. Compliance with Avco Lycoming Instructions No. 1070, and all revision thereto, must be accomplished. 2. While both 100LL or 100 grade fuels are approved, tests conducted for lead fouling char- acteristics of the Lycoming 0-235 engine indicate that use of 100 Low Lead fuel signifi- cantly improves spark plug life and reduces spark plug cleaning requirements. It is rec- ommended that 100LL fuel be used in lieu of 100 grade fuel whenever possible. 3. TCP (Tri-cresyl-phosphate) is a fuel additive used as a "lead fouling inhibitor" for non- turbocharged Lycoming engines. Fuel system components in Cessna aircraft exhibit no detrimental effects from use of TCP when mixed with aviation fuels in accordance with blending table shown in figure 2-2B. SPECIFIED AVIATION GRADE OIL: MAXIMUM OIL AVERAGE AMBIENT TEMPERATURE (°F)/OIL GRADE TEMPERATURE 0° 10° 20 ° 30° 40 ° 50 ° 60 ° 70 ° 80 ° 90° SAE 60 145 SAE 40 or SAE 50 245 SAE 40 245 SAE 30 or SAE 30. SAE 40o SAE W-40 . 15-50 or SAI 20W-50 245 Refer to paragraph 2-21. NOTE The overlap of oil grades is based on a mid-range of ambient ground temperatures vs. maximum oil inlet temperature. Aviation Grade ashless dispersant oil conforming to Avco Lycoming Service Instruction No. 1014. and all revisions and supplements thereto. MUST BE USED except as noted in paragraph 2-21 herein. Oil capacities for the aircraft are given in the following chart. To minimi e loss of oil through the breather. fill to specified oil level on dipstick for normal operation (flight of less than three hours duration). For extended flight, fill to FULL mark on dipstick. Do not operate with less than MINIMUM FOR FLIGHT quantities listed. If an external oil filter is installed, one additional quart of oil is required when filter is changed. CAPACITY CAPACITY (TOTAL NORMAL MINIMUM (TOTAL) WITH FILTER) OPERATION FOR FLIGHT 6 7 55 4 Figure 2-4. Servicing (Sheet 2 of 5) 2-24 Revision I MODEL 152 SERIES SERVICE MANUAL DAILY 03 FUEL TANK FILLER Service after each flight. Keep full to retard condensation. Refer to paragraph 2-18 for details. 4 FUEL TANK SUMP DRAINS Drain off any water and sediment before first flight of the day. 6 PITOT AND STATIC PORTS Check for obstructions before first flight of the day. 10 FUEL STRAINER Drain off any water and sediment before first flight of the day. Refer to paragraph 2-19 for details. 13 INDUCTION AIR FILTER Inspect and service under dusty conditions. Refer to paragraph 2-23 for details. 16 OIL DIPSTICK Check on preflight. Add oil as necessary. Refer to paragraph 2-21 for details. Check that filler cap is tight and oil filler is secure. 18 OIL FILLER CAP Whenever oil is added, check that filler cap is tight and oil filler door is secure. 5 FUEL LINE DRAIN TEE Drain off any water or sediment. Refer to paragraph 2-19. FIRST 25 HOURS 15 ENGINE OIL SYSTEM Drain engine oil sump, clean oil pressure screen, or if equipped. replace oil filter. Re- fill with straight mineral oil Refer to paragraph 2-21. IRST50 HOURS 15 ENGINE OIL SYSTEM Drain engine oil sump, clean oil pressure screen, or if equipped, replace oil filter. Re- fill with ashles disperant oil. Refer to paragraph 2-21. 50 HOURS 15 ENGINE OIL SYSTEM (WHEN NOT EQUIPPED WITH EXTERNAL OIL FILTER) Drain engine sump, clean oil pressure screen, and refill with ashless dispersant oil. NOTE Refer to 100-hour servicing interval when equipped with an external oil filter. Figure 2-4. Servicing (Sheet 3 of 5) Revision 1 2-25 MODEL 152 SERIES SERVICE MANUAL NOTE Engine oil contamination increases possibility of sticking and/or stuck valves. More frequent oil and filter changes (50- hour) will minimize accumulation of harmful contaminants. When the aircraft cannot be flown frequently, the oil and fil- ter should be changed sooner than 50 hour interval. Change oil and filter every 25 hours to eliminate moisture and acids that collect in oil of an inactive engine. 12 NOSE GEAR SHIMMY DAMPENER Check fluid level and refill as required with hydraulic fluid. Refer to paragraph 2-28 for details. 100 HOURS 11 NOSE GEAR SHOCK STRUT Keep strut filled and inflate to correct pressure. Refer to paragraph 2-27 for details. 13 INDUCTION AIR FILTER Clean filter per paragraph 2-23. Replace as required. 14 BATTERY Check electrolyte level each 100 hours or each 30 days. whichever comes first. 7 TIRES Maintain correct tire inflation as listed in figure 1-1. Refer to paragraph 2-26 for details. 5 FUEL LINE DRAIN TEE Drain off any water or sediment. Refer to paragraph 2-19. 10 FUEL STRAINER Disassemble and clean strainer bowl and screen. 15 ENGINE OIL SYSTEM Drain engine oil sump, clean oil pressure screen. change oil filter, or if equipped re- place oil filter. Refill with ashless dispersant oil. Change engine oil at least every 6 months, even though the recommended hours have not accumulated. NOTE Refer to 50 hour servicing interval when not equipped with an external oil filter. NOTE Engine oil contamination increases possibility of sticking and/or stuck valves. More frequent oil and filter changes (50- hour) will minimize accumulation of harmful contaminants. When the aircraft cannot be flown frequently, the oil and fil- ter should be changed sooner than 50 hour interval. Change oil and filter every 25 hours to eliminate moisture and acids that collect in oil of an inactive engine. Figure 2-4. Servicing (Sheet 4 of 5) 2-26 Revision 1 MODEL 152 SERIES SERVICE MANUAL 200 HOURS VACUUM RELIEF VALVE FILTER Remove, discard and replacenew filter every 200 hours. 2 VACUUM SYSTEM CENTRAL AIR FILTER Inspect for damage. 9 BRAKE MASTER CYLINDERS Check fluid level and refill as required with hydraulic fluid. Refer to paragraph 2-28 for details. Landing gear brake master cylinders used prior to 1979 still re- quire overhaul every five years to replace rubber components. Refer to Section 5. 500 HOURS 2 VACUUM SYSTEM CENTRAL AIR FILTER Replace every 500 hours. AS REQUIRED GROUND SERVICE RECEPTACLE Connect to 24-volt DC. negative-ground power unit. Refer to Section 11 for details. Figure 2-4. Servicing (Sheet 5 of 5) Revision 1 2-27 MODEL 152 SERIES SERVICE MANUAL METHOD OF APPLICATION FREQUENCY (HOURS) HAND GREASE OIL SYRINGE GUN CAN (FOR POWDERED GRAPHITE) WHERE NO INTERVAL IS SPECIFIED, LUBRICATE AS REQUIRED AND WHEN ASSEMBLED OR INSTALLED. NOTE The military specifications listed are not mandatory. but are intended as guides in choosing satisfactory materials. Products of most reputable manufacturers meet or exceed these specifications. LUBRICANTS PG- SS-G-659 ....................... POWDERED GRAPHITE GR- MIL-G-81322A ................. GENERAL PURPOSE GREASE GH- MIL-G-23827A ................. AIRCRAFT AND INSTRUMENT GREASE GL- MIL-G-21164C .................. HIGH AND LOW TEMPERATURE GREASE OG- MIL-L-7870A ................... GENERAL PURPOSE OIL PL- VV-P-236 ....................... PETROLATUM GP- ............................... NO. 10-WEIGHT. NON-DETERGENT OIL OL- VV-L-800A ..................... LIGHT OIL Figure 2-5. Lubrication (Sheet 1 of 5) 2-28 MODEL 152 SERIES SERVICE MANUAL \ ENGINE CONTROLS * USE NO LUBRICANT UNDER EXTREME DUSTY CONDITIONS STEERING SYSTEM NEEDLE BEARINGS DAMPENEtR ALS O R E F E R T O PIVOTS PARAGRAPH 2-44 TORQUE LINKS STEERING ARM BEARING ALSO REFER TO PARAGRAPH 2-43 WHEEL BEARINGS NOSE GEAR MAIN GEAR WHEEL BEARINGS Figure 2-5. Lubrication (Sheet 2 of 5) 2-29 MODEL 152 SERIES SERVICE MANUAL BUSHINGS AND CONTROL OILITE BEARINGS WHEEL SHAFT UNIVERSALS BUSHINGS AND OILITE BEARINGS BUSHINGS AND OILITE BEARINGS 4 BATTERY NEEDLE BEARINGS CONTROL "Y" ELEVATOR. TRIM TAB ACTUATOR ALSO REFER TO INSPECTION CHART IN THIS SECTION AND TO SECTION 9 OF THIS MANUAL Figure 2-5. Lubrication (Sheet 3 of 5) 2-30 MODEL 152 SERIES SERVICE MANUAL PG ALL PIANO HINGES AILERON BELLCRANK NEEDLE BEARINGS GL GL TYPICAL CABIN DOOR WINDOW LATCH WING FLAP INDICATOR ROD END BEARINGS PARAGRAPH 2-45 ELECTRIC FLAP DRIVE MECHANISM Figure 2-5. Lubrication (Sheet 4 of 5) 2-31 MODEL 152 SERIES SERVICE MANUAL OILITE BEARINGS (RUDDER BAR ENDS) RUDDER BARS AND PEDALS NOTES Sealed bearings require no lubrication. Do not lubricate roller chains or cables except under seacoast conditions. Wipe with a clean. dry cloth. Lubricate unsealed pulley bearings. rod ends. Oilite bearings. pivot and hinge points. and any other friction point obviously needing lubrication, with general purpose oil every 1000 hours or more often if required. Paraffin wax rubbed on seat rails will ease sliding the seats fore and aft. Lubricate door latching mechanism with MIL-G-81322A general purpose grease, applied sparingly to friction points. every 1000 hours or more often, if binding occurs. No lubrication is recommended on the rotary clutch. Figure 2-5. Lubrication (Sheet 5 of 5) 2-32 MODEL 152 SERIES SERVICE MANUAL 2-46. INSPECTION REQUIREMENTS: As required by Federal Aviation Regulations. all aircraft must undergo a 100 hour and/or annual inspection or may be inspected in accordance with FAA approved Progressive Inspection. 2-47. 100 HOUR AND/OR ANNUAL INSPECTIONS: (Refer to the Inspection Charts. Column 1.) This inspection requires each item marked with a symbol * to be inspected at each 100 hours of flight time and/ or each 12th month following the last inspection recorded for the aircraft. 2-48. SPECIAL INSPECTIONS: (Refer to the Inspection Charts, Column 2.) This inspection requires each item that has a numeral inserted in the column be inspected in accordance with the corresponding numeral listed in the back of the Inspection Charts. 2-49. PROGRESSIVE INSPECTIONS: (Refer to the Inspection Charts. Column 3.) In lieu of the conventional 100 hour/annual inspection as covered in Part 91.169 of the Federal Aviation Regulations, an aircraft may be inspected in accordance with a progressive inspection. Progressive inspection allows the inspection work load to be divided into smaller opera- tions that can be accomplished in a shorter time period and offers increased safety reliability, and utility while decreasing downtime. Aircraft on this program do not require the 100 hour/annual inspection. "Cessna Progressive Care" has been designed for this purpose. It is highly recommended for aircraft being flown 200 hours or more per year NOTE The inspection intervals shown in Column 3 are pres- ented for comparitive purposes only and SHALL NOT BE USED AS THE PROGRESSIVE CARE INSPECTION SCHEDULE. A complete program and operations man- ual are available for this purpose. Cessna Progressive Care has been designed for