CMM 49-94-32

Honeywell International Inc.
2525 West 190th Street

Torrance, CA 90504-6002
U.S.A.
CAGE: 70210
Telephone: (800) 601-3099 (U.S.A.)
Telephone: (602) 365-3099 (International)
Web site: http://portal.honeywell.com/wps/portal/aero
TO: HOLDERS OF OIL COOLER COMPONENT MAINTENANCE MANUAL, 49-94-32, REVISION

NUMBER 002 DATED 17 MARCH 2006.
COMPONENT PART NUMBER APU/ENGINE MODEL NO. AIRCRAFT APPLICATION

160564-1 131-9(B) B-737-600
160564-2 331-600 B-737-700
B-737-800
B-737-900
A340-500
A340-600
REVISION NUMBER 003 DATED 30 APRIL 2008
This is a COMPLETE revision. The pages revised together with the description of the changes are listed under
the Highlights of this revision. Due to the extent of the changes, this publication has been reprinted in its entirety.
Discard the entire manual of previous issue(s) and replace with this complete manual.
The Honeywell disclosure statement has been added to the footer of all pages. All pages have been revised to
the latest template format. Format changes, typographical errors, and re-sequencing of data do not have a
revision bar and are not listed in the Highlights. Technical changes, error corrections, and added data have a
revision bar. Changes to the Detailed Parts List are identified by an R adjacent to the Units per Assy column.
PAGE HIGHLIGHTS
Subject/Page Description of Change
Title Page
Pages T-1 and T-2 Changed revision number and date.
List of Effective Pages
Pages LEP-1 and LEP-2 Changed all dates.
Page 9 Revised leakage repair instructions.
49-94-32 HIGHLIGHTS Page 1 of 2

Oct 25/96
Rev 3, Apr 30/08
©Honeywell International Inc. Do not copy without express permission of Honeywell.
COMPONENT MAINTENANCE MANUAL
160564
PAGE HIGHLIGHTS (CONTINUED)

Subject/Page Description of Change
Repair
Pages 33 Revised general repair procedures to add
overhaul repair instructions (ORI) reference.
Revised caution to incorporate TR 49-1.
Revised specification and nomenclature.
Special Tools, Fixtures, and Equipment
Page 48 Added equipment not previously listed in Table
9.
49-94-32 Page 2 of 2
Oct 25/96
Rev 3, Apr 30/08
Honeywell International Inc.
2525 West 190th Street
Torrance, CA 90504-6002
U.S.A.
CAGE: 70210
Telephone: (800) 601-3099 (U.S.A.)
Telephone: (602) 365-3099 (International)
Web site: http://portal.honeywell.com/wps/portal/aero

WITH
ILLUSTRATED PARTS LIST
OIL COOLER
COMPONENT PART NUMBER APU/ENGINE MODEL NO. AIRCRAFT APPLICATION

160564-1 131-9(B) B-737-600
160564-2 331-600 B-737-700
B-737-800
B-737-900
A340-500
A340-600
This document contains technical data and is subject to U.S. export regulations. These commodities,
technology, or software were exported from the United States in accordance with the export administration
regulations. Diversion contrary to U.S. law is prohibited.
ECCN: 9E991, no license required.
49-94-32 Page T-1

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Rev 3, Apr 30/08
160564
Honeywell – Confidential
THIS COPYRIGHTED WORK AND ALL INFORMATION ARE THE PROPERTY OF HONEYWELL
INTERNATIONAL INC., CONTAIN TRADE SECRETS AND MAY NOT, IN WHOLE OR IN PART, BE USED,
DUPLICATED, OR DISCLOSED FOR ANY PURPOSE WITHOUT PRIOR WRITTEN PERMISSION OF
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The documents and information contained herein (“the Materials”) are the proprietary data of Honeywell
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are provided for the exclusive use of Honeywell Service Centers; Honeywell-authorized repair facilities;
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49-94-32 Page T-2

Apr 30/08

160564
6. Term - This License Agreement is effective until terminated as set forth herein. This License Agreement will terminate
immediately, without notice from Honeywell, if you fail to comply with any provision of this License Agreement or will
terminate simultaneously with the termination or expiration of your applicable product support agreement, authorized repair
facility agreement, or your formal designation as a third party service provider. Upon termination of this License Agreement,
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7. Remedies - Honeywell reserves the right to pursue all available remedies and damages resulting from a breach of this
License Agreement.
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Materials. THERE ARE NO OTHER WARRANTIES, WHETHER WRITTEN OR ORAL, EXPRESS, IMPLIED OR
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WHETHER LIABILITY ARISES FROM BREACH OF CONTRACT, WARRANTY, TORT (INCLUDING BUT NOT LIMITED TO
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9. Controlling Law - This License shall be governed and construed in accordance with the laws of the State of New York
without regard to the conflicts of laws provisions thereof. This license sets forth the entire agreement between you and
Honeywell and may only be modified by a writing duly executed by the duly authorized representatives of the parties.
Copyright - Notice
Copyright 1996, 2008 Honeywell International Inc. All rights reserved.
Honeywell is a registered trademark of Honeywell International Inc.

All other marks are owned by their respective companies.
49-94-32 Page T-3

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49-94-32 Page T-4

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SAFETY ADVISORY
WARNING: BEFORE THE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED,
KNOW THE HANDLING, STORAGE AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO
OBEY THE MANUFACTURERS' OR SUPPLIERS' RECOMMENDATIONS CAN
RESULT IN PERSONAL INJURY OR DISEASE.
This publication describes physical and chemical processes which can make it necessary to use
chemicals, solvents, paints, and other commercially available materials. The user of this
publication must get the Material Safety Data Sheets (OSHA Form 20 or equivalent) from the
manufacturers or suppliers of the materials to be used. The user must know the manufacturer/
supplier data and obey the procedures, recommendations, warnings and cautions set forth for the
safe use, handling, storage, and disposal of the materials.
WARRANTY/LIABILITY ADVISORY
WARNING: HONEYWELL ASSUMES NO RESPONSIBILITY FOR ANY HONEYWELL

EQUIPMENT WHICH IS NOT MAINTAINED AND/OR REPAIRED IN
ACCORDANCE WITH HONEYWELL'S PUBLISHED INSTRUCTIONS AND/OR
HONEYWELL'S FAA/SFAR 36 REPAIR AUTHORIZATION. NEITHER DOES
HONEYWELL ASSUME RESPONSIBILITY FOR SPECIAL TOOLS AND TEST
EQUIPMENT FABRICATED BY COMPANIES OTHER THAN HONEYWELL.
INCORRECTLY REPAIRED COMPONENTS CAN AFFECT AIRWORTHINESS

OR DECREASE THE LIFE OF THE COMPONENTS. INCORRECTLY
FABRICATED SPECIAL TOOLING OR TEST EQUIPMENT CAN RESULT IN
DAMAGE TO PRODUCT COMPONENTS OR GIVE UNSATISFACTORY
RESULTS.
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RECORD OF REVISIONS
REV ISSUE DATE REV ISSUE DATE
NO. DATE INSERTED BY NO. DATE INSERTED BY
ORIG Oct 25/96
1 Dec 15/01
2 Mar 17/06
3 Apr 30/08
Page RR-1
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Blank Page
Page RR-2
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RECORD OF TEMPORARY REVISIONS

INCORPO-
RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
49-1 32 Mar 31/04 2
Page TR-1
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160564
Blank Page
Page TR-2
49-94-32 Apr 30/08
©Honeywell International Inc. Do not copy without express permission of Honeywell..
160564
SERVICE BULLETIN LIST
Date
SB No. Incorporated Title/Description
49-2376 Mar 17/06 Replace 160564-1 with 160564-2, which has the epoxy
phenolic coating.
SPARE PARTS BULLETIN LIST
Date of Date
SPB No. Bulletin Incorporated Title
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Blank Page
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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Page T-1 Apr 30/08 Testing and

T-2 Apr 30/08 Fault Isolation
T-3 Apr 30/08 (cont) 9 Apr 30/08
T-4 Apr 30/08 10 Apr 30/08
Safety/Warranty/ Disassembly 11 Apr 30/08

Liability Advisory SWLA-1 Apr 30/08
SWLA-2 Apr 30/08 Cleaning 12 Apr 30/08
13 Apr 30/08
Record of 14 Apr 30/08
Revisions RR-1 Apr 30/08 15 Apr 30/08
RR-2 Apr 30/08 16 Apr 30/08
17 Apr 30/08
Record of 18 Apr 30/08
Temporary 19 Apr 30/08
Revisions TR-1 Apr 30/08 20 Apr 30/08
TR-2 Apr 30/08 21 Apr 30/08
22 Apr 30/08
Service/Spare 23 Apr 30/08
Parts Bulletin List SB-1 Apr 30/08 24 Apr 30/08
SB-2 Apr 30/08 25 Apr 30/08
26 Apr 30/08
List of Effective 27 Apr 30/08
Pages LEP-1 Apr 30/08 28 Apr 30/08
LEP-2 Apr 30/08
Check 29 Apr 30/08
Table of Contents TC-1 Apr 30/08 30 Apr 30/08
TC-2 Apr 30/08
Repair 31 Apr 30/08
Introduction INTRO-1 Apr 30/08 32 Apr 30/08
INTRO-2 Apr 30/08 33 Apr 30/08
34 Apr 30/08
Description 35 Apr 30/08
and Operation 1 Apr 30/08 36 Apr 30/08
2 Apr 30/08 37 Apr 30/08
38 Apr 30/08
Testing and 39 Apr 30/08
Fault Isolation 3 Apr 30/08 40 Apr 30/08
4 Apr 30/08 41 Apr 30/08
5 Apr 30/08 42 Apr 30/08
6 Apr 30/08 43 Apr 30/08
7 Apr 30/08 44 Apr 30/08
8 Apr 30/08 45 Apr 30/08
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LIST OF EFFECTIVE PAGES (CONTINUED)

SUBJECT PAGE DATE
Assembly
(With Storage) 46 Apr 30/08
47 Apr 30/08
Special Tools,
Fixtures, and
Equipment 48 Apr 30/08
Illustrated Parts
List 49 Apr 30/08
50 Apr 30/08
51 Apr 30/08
52 Apr 30/08
53 Apr 30/08
54 Apr 30/08
55 Apr 30/08
56 Apr 30/08
Page LEP-2
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TABLE OF CONTENTS
Section Page
Introduction ..................................................................................................................... INTRO-1

Description and Operation ...........................................................................................................1
Testing and Fault Isolation ...........................................................................................................3
Automated Test Requirements (ATLAS) (Not Applicable)
Disassembly ...............................................................................................................................11
Cleaning .....................................................................................................................................12
Check .........................................................................................................................................29
Repair ........................................................................................................................................31
Assembly (With Storage) ...........................................................................................................46
Fits and Clearances (Not Applicable)
Special Tools, Fixtures, and Equipment ....................................................................................48
Illustrated Parts List ...................................................................................................................49
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INTRODUCTION
This publication gives maintenance instructions with Illustrated Parts List (IPL) for the Oil Cooler
(part number shown in the Equipment Identification List below) made by Honeywell International,
Inc., Torrance, California (Commercial and Government Entity (CAGE) Code 70210).
The instructions in this manual give information necessary to do maintenance functions, from
simple checks and replacement to complete shop-type repair.
The manual is divided into separate sections as follows:
1. Title Page 5. List of Effective Pages
2. Record of Revisions 6. Table of Contents
3. Record of Temporary Revisions 7. Introduction
4. Service Bulletin List 8. Procedures and IPL
Refer to the Table of Contents for page location of applicable procedure section.
This publication is written to the Air Transport Association of America (ATA) Specification No. 100.
An explanation of how to use the Illustrated Parts List is provided in the Introduction to that section.
If measurements, weights, dimensions, temperatures, pressure or torque values are changed to
metric equivalents, they are shown in parentheses after the standard United States
measurements.
The manual will be revised as necessary to show current information.
Equipment Identification List
IPL Service
Part No. Series No. Use Code Description Bulletin
160564-1 1 A Qualification test unit. -
160564-1 2 B Added holes in weld assembly. -
160564-1 3 C Added black paint and epoxy coating. -
160564-1 4 D Machined flange. -
160564-2 3 E Added black paint and epoxy coating. 49-2376
160564-2 4 F Machined flange. 49-2376
Page INTRO-1
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The following sections of this publication have been verified on the date(s) specified. Where actual
performance of the procedures cannot be done before issuing a manual, those procedures will be
verified by simulation. Any procedures verified by simulation must be verified by actual
performance at the earliest possible time.
VERIFIED SECTION VERIFICATION METHOD VERIFICATION DATE
Testing and Fault Isolation Verified by simulation Oct 10/96

Disassembly Verified by simulation Oct 10/96
Assembly Verified by simulation Oct 10/96
Page INTRO-2
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1. DESCRIPTION AND OPERATION
A. Description
(1) The oil cooler (hereafter referred to as the cooler) is made up of an
aluminum core assembly with an oil return pan on one end and an oil
inlet/outlet manifold on the other end. The core assembly has an
attachment mounting flange welded to the cooling air outlet side. The core
assembly has fins which are separated by tube plates to form air and oil
passages running perpendicular to each other through the cooler.
Refer to Figure 1.
Oil Cooler
Figure 1
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B. Operation
(1) Hot oil enters the cooler through the oil inlet port, flows through the
connecting layers of fins within the core assembly, and exits through the oil
outlet port. Heat from the oil is conducted through the fins and is transferred
to the cooling air flowing through the cross flow layer of fins. This transfer
of heat through the fins cools the hot oil as the oil passes through the cooler.
C. Leading Particulars
(1) Refer to Table 1 for leading particulars.
Table 1. Leading Particulars
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aluminum, air to oil

Proof Test Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 to 210 psig, at 60 to 120°F
(1379 to 1448 kPa, at 15,5 to 48,8°C)
Dimensions:
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.16 in. (537,464 mm) (approx)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.50 in. (241,3 mm) (approx)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.98 in. (101,092 mm) (approx)
Dry weight
Part No. 160564-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.65 lb (3,92 kg) (max)
Part No. 160564-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.73 lb (3,96 kg) (max)
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2. TESTING AND FAULT ISOLATION
A. Equipment and Materials
(1) Standard shop equipment and materials, along with the items shown in
Table 2, can be used to do the tests on the cooler.
Table 2. Equipment and Materials
Equipment/Material Description/Manufacturer
NOTE: Equipment/materials that meet or exceed given parameters can be used.
Compressed air or nitrogen source Customer furnished

(0 to 250 psig (0 to 1725 kPa)
±5 psig (34,5 kPa))
Oil (MIL-PRF-7808 or MIL-PRF-23699) Customer furnished
EQUIPMENT
Differential pressure gage (oil) Dresser Industries Instrument Div

(Ashcroft 60-1125-A-02L-60PSI) 250 E. Main Street
(0 to 60 psid (0 to 413 kPd) Stratford, CT 06614-5145 (V38056)
±1 psid (6,9 kPd))
Electric motor (for hydraulic pump) U.S. Electrical Motors

(Model A958) (3 HP, 1200 rpm) 8100 West Floissant Avenue
St. Louis, MO 63136
Hydraulic pump Roper Industries Inc

(Model A12 with bracket N44-214) P.O. Box 269
(10 gpm (37,85 lpm) min) Commerce, GA 30529 (V55860)
Oil heater/cooler Customer furnished

(130 to 180°F (54,44 to 82°C)
±3°F (1,67°C))
Pressure gage (air) Dresser Industries Instrument Div

(Ashcroft 35-1009-SW-02L-300PSI) 250 E. Main Street
(0 to 250 psig (0 to 1725 kPa) Stratford, CT 06614-5145 (V38056)
±1 percent of full scale)
Safety water tank Customer furnished

(Sufficient size to fully submerge the cooler)
Shutoff valves Customer furnished

(2 required)
Thermocouple and electronic readout Newport Electronics Inc

(TC-J-NPT-72/N and 205-JC2-R-C0) 2229 S. Yale Street
(130 to 180°F (54,44 to 82°C) Santa Ana, CA 92704-4426 (V32873)
±3°F (1,67°C))
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Table 2. Equipment and Materials (Continued)
Timer Customer furnished

(0 to 5 minutes, ±1 second)
Turbine flowmeter and electronic readout Flowmetrics Inc

(FM-10-N-X-12.5-LD-1-L and 202-4-0) 9201 Independence Avenue
(10 gpm (37,85 lpm) ±0.2 gpm (0,75 lpm)) Chatsworth, CA 91311-5905 (V54679)
SPECIAL TOOLS
Pressure test plug set Honeywell Ground Support Solutions

(2024572-1) 717 N. Bendix Drive
South Bend, IN 46628-1000
Pressure drop tube set Honeywell Ground Support Solutions

(2024573-1) 717 N. Bendix Drive
B. General Test Information

WARNING: HIGH PRESSURE IS USED TO DO THE TESTS. BEFORE YOU
APPLY PRESSURE TO THE COOLER, MAKE SURE THAT ALL
CONNECTIONS, HOSES, AND TEST APPARATUS ARE
CORRECTLY ATTACHED TO PREVENT LOSS OF
CONTAINMENT AND POSSIBLE INJURY TO PERSONNEL
WHEN THE COOLER IS UNDER PRESSURE. CARE MUST BE
TAKEN TO PROTECT PERSONNEL AND SURROUNDINGS
FROM EXPLOSION.
CAUTION: DO NOT EXPOSE THE COOLER INTERIOR OIL PASSAGES TO
WATER OR MOISTURE AT ANY TIME. USE ONLY DRY AIR OR
THE OIL AND CALIBRATING FLUIDS SPECIFIED IN TABLE 2
WHEN YOU DO THE TESTS. DAMAGE DUE TO CORROSION
CAN BE DIFFICULT TO DETECT AND CAN CAUSE FAILURE OF
THE COOLER.
CAUTION: HANDLE THE COOLER WITH CARE. THE CAST AIR INLET
FLANGE OF THE COOLER IS EXTREMELY FRAGILE AND CAN
BE EASILY BENT UNDER THE COOLER WEIGHT. DO NOT USE
THE INLET FLANGE TO PICK UP THE COOLER. DAMAGE TO
THE COOLER CAN RESULT. TRANSPORT THE COOLER IN AN
APPROPRIATE PACKING CONTAINER.
(1) Make sure the cooler has no visible cracks, dents, or other damage before
you do the tests.
(2) Do all the tests at laboratory ambient conditions unless specified differently
in the test descriptions.
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(3) You must clean the cooler fully before you do the testing in order to get the
correct test results. Refer to the CLEANING section.
C. Proof Pressure and Leakage Test
CAUTION: DURING ANY PNEUMATIC PRESSURE TEST, CARE MUST BE
TAKEN TO PROTECT PERSONNEL AND SURROUNDINGS
AGAINST THE EXPLOSION HAZARD.
(1) Use pressure test plug set (2024572-1) to seal the oil inlet and oil outlet
ports. Cap one of the plug fittings. Either port can be used to pressurize the
cooler.
(2) Install the cooler in a test setup. Refer to Figure 2.
NOTE: If facility air system is used, air must be filtered to remove oil,
moisture and solid particles.
(3) Connect a regulated pressure source of room temperature air or nitrogen
to the pressure fitting of the plug set. Leave the cooling air passages of the
cooler open to ambient.
(4) Fill a safety water tank with enough water to fully submerge the cooler. Put
the cooler fully in safety water tank.
WARNING: BEFORE YOU APPLY PRESSURE TO THE COOLER, MAKE
SURE THAT ALL CONNECTIONS, HOSES, AND TEST
APPARATUS ARE CORRECTLY ATTACHED TO PREVENT
INJURY TO PERSONNEL WHEN COOLER IS UNDER
PRESSURE.
(5) Apply pneumatic pressure of 200 to 210 psig (1379 to 1448 kPa) at
60 to 120°F (15,5 to 48,8°C).
(6) Close the supply valve. Hold the pressure in the cooler for five minutes,
minimum.
(7) Examine the outside surfaces of the cooler for external leakage. Leaks will
appear as escaping bubbles. No external leakage is permitted.
(8) Slowly decrease the pressure to ambient. Remove the cooler from the
water tank. Examine the cooler for permanent deformation. There must be
no permanent deformation.
WARNING: USE CORRECT PROTECTION. COMPRESSED AIR WILL
REMOVE LOOSE PARTICLES THAT CAN GET IN YOUR EYES.
THE AIRSTREAM CAN CAUSE CUTS. DO NOT POINT THE
AIRSTREAM TOWARD YOURSELF OR OTHER PERSONS.
(9) Use a dry, oil-free compressed air source at 20 to 30 psig
(137,9 to 206,8 kPa) to remove as much water as possible from the cooler.
(10) Remove the pressure test plug set (2024572-1) from the oil inlet and outlet
ports of the cooler.
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Proof Pressure and Leakage Test Setup

Figure 2
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WARNING: USE CORRECT PROTECTION. HEATED PARTS CAN CAUSE
BURNS.
(11) Dry the cooler (within 24 hours) in an oven at 225 to 275°F (107,2 to 135°C)
for two hours minimum, or until the cooler is fully dry. Leave all ports open
to let hot air flow through the cooler.
D. Oil Pressure Drop Test
(1) Use the pressure drop tube set (2024573-1) to seal the oil inlet and oil outlet
ports. Install the cooler in a test setup. Refer to Figure 3.
(2) Connect the pressure fittings to a source of circulating oil that can supply a
flow of 9.1 to 9.7 gal/min (34,4 to 36,7 l/min) at 175 to 185°F (79,4 to 85°C).
(3) Start an oil flow of 9.1 to 9.7 gal/min (34,44 to 36,71 l/min) at 175 to 185°F
(79,4 to 80°C) through the cooler. Let the temperature become stable.
(4) The pressure drop across the cooler must be between 6 to 12 psid
(41,4 to 82,7 kPd).
(5) Decrease the oil flow to zero and remove the cooler from the test setup.
(6) Remove the pressure drop tube set (2024573-1) from the cooler.
(7) Drain unwanted oil from the cooler.
E. Cleanliness Test
(1) The following procedure can be done to test the cleanliness of the interior
oil passages. It can be done before final testing of the cooler and is also
recommended for coolers where metal contamination is suspected, to
make sure the interior passages are clean. Flush and examine the cooler.
Refer to the paragraph 4. F. Internal Oil Passage Cleaning.
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Oil Pressure Drop Test Setup

Figure 3
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F. Fault Isolation
(1) Refer to Table 3 for fault isolation information.
Table 3. Fault Isolation
Trouble Probable Cause Correction
Proof Pressure and Leakage Test (Para. 2. C.)
Signs of permanent Side plates or oil pans are Cooler is no longer serviceable.
deformation structurally weak Replace cooler.
Leakage from oil inlet Pressure test plug set o-ring Replace pressure test plug set
or outlet ports seals missing or worn o-ring seals and do test again.
Studs (20, IPL Figure 1) are Replace studs (20). Refer to the
crossed, stripped or worn REPAIR section.
Damaged cooler Replace cooler.
Leakage from cooler Side plates punctured or Refer to the REPAIR section.
side plates cracked
Leakage from oil inlet or Oil manifold punctured Repair oil manifold leakage.
outlet manifolds or cracked Refer to the REPAIR section.
Leakage of manifold-to-core Open weld or seam Refer to the REPAIR section.

weld joints
Leakage from cooler Leakage from core oil Repair oil passage leak.
core face passage to cooling air Refer to the REPAIR section.
passage
Oil Pressure Drop Test (Para. 2. D.)
Pressure decay above limit Oil flow passages are not Clean the cooler internal
clean passages. Refer to the
CLEANING section.
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Table 3. Fault Isolation (Continued)
Trouble Probable Cause Correction
Cleanliness Test (Para. 2. E.)
Particles can still be seen Oil flow passages are not Clean the cooler internal
clean passages. Refer to the
CLEANING section.
Pressure Flow Test (Refer to the CLEANING section)
Air flow not within limits Air passages are blocked Examine and straighten core
fins. Refer to the REPAIR
section. Clean air passages.
Refer to the CLEANING
section. If air flow limits cannot
be met, cooler is no longer
serviceable. Replace cooler.
Page 10
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3. DISASSEMBLY
(1) Standard shop equipment and materials can be used to disassemble the
cooler.
B. General Disassembly Procedures
CAUTION: BE CAREFUL TO PREVENT DAMAGE TO PARTS THAT CAN BE
USED AGAIN.
(1) Do all disassembly procedures in a dry, correctly lighted area that is free
from dust.
NOTE: Refer to the TESTING AND FAULT ISOLATION section to find
the condition of the cooler and the level of disassembly
necessary to repair the cooler.
(2) Remove all protective caps, plugs, and closures before disassembly of the
cooler.
(3) Honeywell recommends that the parts shown in Table 4 be replaced at
each disassembly. Actual replacement of parts, however, can depend on
the condition of the part and the operator’s in-service experience.
Table 4. Parts to be Replaced at Each Disassembly
Item No. (IPL Figure 1) Nomenclature Quantity
13 Packing 2
C. Detailed Disassembly Procedures

(1) Do not remove the ident plate (10, IPL Figure 1) unless it is damaged or you
can not read it. Refer to the REPAIR section for replacement of
ident plate (10).
(2) Remove packings (13) from the welded assembly (30). Discard the
packings.
(3) Remove the nuts (15) from the studs (20).
(4) Do not remove the studs (20) from the welded assembly (30) unless
necessary after check. Refer to the REPAIR section for replacement of
studs (20).
(5) Do not remove the screws (25) from the welded assembly (30) unless
necessary after check. Refer to the REPAIR section for replacement of
screws (25).
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4. CLEANING
Table 5, can be used to clean the cooler.
Abrasive Blasting Media:
* Sodium bicarbonate media (Armex) Church & Dwight Co. Inc

469 N. Harrison Street
Princeton, NJ 08540-3510 (V90038)
* Solid carbon dioxide media (CO2 Cleanblast) CAE Alpheus Inc

9119 Milliken Avenue
Rancho Cucamonga, CA 91730 (VOH4G2)
* Starch blast media (Envirostrip) Ogilvie Mills Inc

6121 Baker Rd, Suite 101
Hopkins, MN 55345 (V0PLE7)
Plastic blasting media U.S.Technology Corp

(Industrial Polyplus, 30 to 80 grit) 1446 West Tuscarawas Street
Canton, OH 44702-2038 (V1AM56)
Aqueous Cleaning Solution:
* Cleaner (MIL-PRF-85704, Type II or IIA) Customer furnished
* * TC-100 B&B Tritech Inc

101 East Baseline Road
Gilbert, AZ 85234 (V0UTM6)
Flushing Solvents:
* Actrel 3360L Safety-Kleen Systems Inc

5400 Legacy Drive Cluster II
Building 3
Plano, Texas 75204 (V30530)
Solvent Customer furnished

(MIL-PRF-680, Type II or MIL-PRF-7808)
* Alternate material
* * The cleaner (TC-100) is referenced in the Qualified Products List (QPL) for MIL-PRF-85704.
NOTE: Alternative means either material can be used and that one is not better than the other.
Page 12
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Paint /Coating Strippers: (Immersion type)
* Turco 5668L Henkel Surface Technologies Div

Turco Products Turco Aviation
32100 Stephenson Highway
Madison Heights, MI 48071 (V1N6B3)
K-2581 Chem Arrow Corp International

13643 E. Live Oak, P.O. Box 2366
Baldwin park, CA 91706 (V0AKX3)
Paint/Coating Strippers: (Brush-on type)
Turco 6776 Henkel Surface Technologies Div

Preservative Oil:
Preservative oil Customer furnished

(MIL-PRF-23699 or MIL-PRF-8188)
Steam Cleaning Solutions:
* Aluminum cleaner Henkel Surface Technologies Div

(Ridoline 909) (MIL-S-5002) Turco Products Turco Aviation
* Citrus Cleaner 144 T and L Speciality Co.

300 Airpark Road
Tupelo, MS 38801 (V3FRF3)
* Detergent (N.R.G. Plus No. 678) National Colloid Research and

Development Inc
411 East Columbine Avenue
Santa Ana, CA 92707 (V5R313)
* Detergent (Turco 1685) Henkel Surface Technologies Div

Page 13
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Steam Cleaning Solutions: (Cont)
* * TC-100 B&B Tritech Inc

101 East Baseline Road
Gilbert, AZ 85234 (V0UTM6)
EQUIPMENT
Air temperature probe/thermocouple Newport Electronics Inc

(EQSS-14G-12/N) 2229 S. Yale Street
(Chromel/Constanten, ANSI Type E) Santa Ana, CA 92704-4426 (V32873)
Barometer (Model L-03316-80) The Scott Fetzer Company

(27.7 to 30.9 in. (703,6 to 785 mm) HgA) Meriam Process Technologies Div
Meriam Instrument
10920 Madison Avenue
Cleveland, OH 44102-2599 (V39739)
Flow measuring section Daniel Industries Inc

(4-40-M30RW-2.5-304SS) 9270 Katy Road
(0 to 200 lb/min (0 to 90,7 kg/min)) P.O. Box 19097
(Honeywell recommends a 4.0 in. (101,6 mm) Houston, TX 77024 (V15916)
line with a 2.5 in. (63,5 mm) orifice)
Inspection filter Whatman Air Filtration Inc

(10 micron MF-Millipore Type SC or Millipore 1885 Norman Avenue
Mitex Type LC, patch) Santa Clara, CA 95054-0000
Pressure indicator (Model 661-D/C140) Wallace & Tiernan Inc

(0 to 80 in. (0 to 2032 mm) H2O) 1901 West Garden Road
Vineland, NJ 08360-1530 (V79172)
Temperature readout (Model 269) Newport Electronics Inc

(Digital, 32.36°F (0,2°C) accuracy) 2229 S. Yale Street
Santa Ana, CA 92704-4426 (V32873)
SPECIAL TOOLS
Air flow test adapter (2024585-1) Honeywell Ground Support Solutions

(Cooling air inlet) 717 N. Bendix Drive
Page 14
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SPECIAL TOOLS (Cont)
Pressure test plug set (2024572-1) Honeywell Ground Support Solutions

(Oil inlet and outlet ports) 717 N. Bendix Drive
Pressure drop tube set (2024573-1) Honeywell Ground Support Solutions

(Oil inlet and outlet ports) 717 N. Bendix Drive
B. General Information
WARNING: BEFORE THE MATERIALS CALLED OUT IN THIS PUBLICATION
ARE USED, KNOW THE HANDLING, STORAGE AND DISPOSAL
PRECAUTIONS RECOMMENDED BY THE MANUFACTURER
OR SUPPLIER. FAILURE TO COMPLY WITH THE
MANUFACTURER’S OR SUPPLIER’S RECOMMENDATIONS
CAN RESULT IN PERSONAL INJURY OR DISEASE.
(1) This section describes physical and chemical processes that can make it
necessary to use chemicals, compounds, solvents, and other commercially
available materials. The user of this publication must get the Material Safety
Data Sheets (OSHA Form 20 or equivalent) from the manufacturers or
suppliers of the materials to be used. The user must know the
manufacturer/supplier information and keep to the procedures,
recommendations, warnings and cautions set forth for the safe use,
handling, storage, and disposal of the materials.
CAUTION: HANDLE THE COOLER WITH CARE. THE AIR INLET AND
OUTLET FLANGE OF THE COOLER IS VERY FRAGILE AND
CAN BE EASILY BENT UNDER THE COOLER WEIGHT. DO NOT
USE THE INLET AND OUTLET FLANGES TO PICK UP THE
COOLER. DAMAGE TO THE COOLER CAN RESULT.
TRANSPORT THE COOLER IN AN APPLICABLE PACKING
CONTAINER.
(2) This section gives different procedures for cleaning the cooler. Any or all of
these procedures can be used, omitted, or done again as necessary to
clean the cooler.
(3) After the cooler has been cleaned, a Cooling Air Pressure Flow Test can be
done to make sure the cooling air passages have been correctly cleaned.
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(4) After completion of repairs and before final storage of the cooler, do the
Particle Flush and Check to make sure the internal passages are free of
contaminants.
C. Detailed Cleaning Procedures
WARNING: USE CORRECT PROTECTION IN AN AREA WITH A GOOD
FLOW OF AIR. SOLVENT CAN CAUSE SKIN, EYE, AND
RESPIRATORY DAMAGE. DO NOT USE NEAR AN OPEN
FLAME.
(1) Clean the bypass valve components and external surfaces of the cooler to
remove oil, grease, rust, and dirt with a cloth moist with solvent.
(2) Remove dirt or build-up on the cooler valve port with solvent and a soft
bristle brush.
D. Air Passage and External Surface Cleaning
(1) Cleaning Preparation. Prepare the cooler for cleaning as follows:
REMOVE LOOSE PARTICLES THAT CAN GET IN YOUR
EYES. THE AIRSTREAM CAN CAUSE CUTS. DO NOT
POINT THE AIRSTREAM TOWARD YOURSELF OR AT
OTHER PERSONS.
(a) Use a dry, oil-free compressed air source at 20 to 30 psig
(137,9 to 206,8 kPa) to remove as much loose particles and
contamination as possible.
(b) Install pressure test plug set (2024572-1) in the oil inlet and outlet
ports to keep cleaning solution (other than approved steam cleaning
solutions) out of the oil passages.
(2) Aqueous Cleaning. The following cleaning procedure uses a solution to
remove oil, grease, dirt and carbon deposits from the cooling air passages
and external surfaces of the cooler. Clean the cooler as follows:
WARNING: REFER TO PARAGRAPH 4. B. FOR THE APPLICABLE
WARNING NOTICE BEFORE YOU USE ANY OF THE
FOLLOWING CHEMICALS. USE ONLY IN
WELL-VENTILATED AREA.
(a) Put the cooler fully in a tank of aqueous cleaning solution. The
cooler can be tilted to various angles when submerged in the
solution to make sure that air pockets in the cooler are removed.
NOTE: The TC-100 solution (or other MIL-PRF-85704, Type IIA
cleaners) can be used at full concentration. Use
alternative MIL-PRF-85704, Type II cleaners at
concentrations recommended by the manufacturer.
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(b) The solution can be heated as given in the manufacturer's
recommendations, power flushed through the cooler, or the cooler
can be shaken to speed the cleaning process.
CAUTION: DO NOT PUT THE COOLER IN THE CLEANING
SOLUTION FOR MORE THAN FOUR HOURS (TOTAL
EXPOSURE TIME). PROLONGED EXPOSURE TO THE
CLEANING SOLUTION CAN RESULT IN DAMAGE TO
THE COOLER.
(c) Keep the cooler in the solution for a maximum of four hours (total
exposure time).
(d) Rinse the exterior surfaces and air passages of the cooler with
clean water to remove contamination. This can be done by
submerging the cooler in a tank of water several times until the
water drains free of contamination.
(3) Steam Cleaning. Steam clean the cooler to remove remaining solution or
contamination from the cooler. Steam cleaning can be done on the interior
oil passages if the cooler is fully dried within four hours after cleaning. Refer
to paragraph 4. D. (5) Oven Drying. Steam clean the cooler as follows:
WARNING: WEAR PROTECTIVE CLOTHING, EYE SHIELDS AND
RUBBER GLOVES WHEN YOU USE STEAM CLEANING
EQUIPMENT.
(a) Clean the internal oil passages and exterior surfaces of the cooler
with water at 25 to 30 psig (172,4 to 206,8 kPa). A small amount of
detergent can be added to the water to help in the cleaning process.
CAUTION: KEEP THE TIP OF THE STEAM CLEANER SPRAY WAND
A MINIMUM OF 12 INCHES (305 MM) AWAY FROM THE
CORE FINS. DAMAGE TO THE CORE FINS CAN RESULT
FROM TOO MUCH STEAM PRESSURE.
(b) Direct the spray through the cooling air tube passages of the cooler
until there are no visible contaminants in the outlet. Turn the cooler
and direct the spray through the air inlet until there are no visible
contaminants in the inlet. Do this procedure several times until the
water runs free of contaminants.
(c) Flush the interior oil passages and exterior surfaces of the cooler
with clean water to remove any residue. This can be done by
submerging the cooler in a tank of water several times until the
water runs free of contaminants.
(d) Fully dry the cooler. Refer to the paragraph 4. D. (5) Oven Drying.
(e) If this is the last cleaning step, preserve the internal oil passages.
Refer to the paragraph 4. H. Internal Oil Passage Preservation.
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(4) Vibration Table. Do the following procedure to remove loose contamination
from the cooler and examine for cleanliness. Clean and examine the cooler
as follows:
OTHER PERSONS.
(a) Use compressed air at 20 to 30 psig (137,9 to 206,8 kPa) to remove
as much loose particles and debris as possible.
WARNING: USE CORRECT PROTECTION. HEATED PARTS CAN
CAUSE BURNS.
(b) Use masking tape to cover oil inlet and outlet ports. Put the cooler
in an oven at a temperature of 225 to 275°F (107,2 to 135°C).
(c) Put the cooler on a vibration table and vibrate the cooler while still
hot.
(d) Remove the tape from oil inlet and outlet ports and examine
adhesive side of tape for foreign material. A cooler that has been
cleaned correctly will have no material on the tape that you can see.
(e) Do the cleaning procedures in steps (a) through (d) as necessary to
correctly clean the cooler.
(5) Oven Drying. The following procedure must be done to remove moisture
from inside the cooler. To prevent corrosion, the cooler must be fully dried
within four hours after completion of wet cleaning process and before
shipping or storage of the cooler. Dry the cooler as follows:
OTHER PERSONS.
(a) Use a dry, oil-free compressed air source at 20 to 30 psig
(137,9 to 206,8 kPa) to remove as much water as possible from the
cooler.
WARNING: REMOVE ALL PLUGS OR CAPS BEFORE YOU PUT THE
COOLER IN THE OVEN. THE EXPANSION OF TRAPPED
GASES INSIDE A PLUGGED COOLER CAN RESULT IN
INJURY OR DAMAGE TO THE COOLER.
(b) Remove pressure test plug set (2024572-1) from the oil inlet and
outlet ports of the cooler.
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CAUSE BURNS.
(c) Put the cooler in an oven at a temperature of 225 to 275°F
(107,2 to 135°C) and bake for two hours minimum, or until the
cooler is fully dry. Keep ports open to let air flow freely.
OTHER PERSONS.
(d) Remove cooler from oven and while it is still hot, blow with dry,
oil-free compressed air at a source pressure of 20 to 30 psig
(137,9 to 206,8 kPa) through all passages to remove moisture.
(e) If moisture remains in the cooler, do steps (c) and (d) again until the
cooler is fully dry.
E. Coating Stripping
(1) Mechanical Stripping. The following procedure can be done to remove
epoxy coating, and cosmetic defects such as minor corrosion from outer
surfaces of cooler only. Replacement of the coatings from the area stripped
will be necessary after repair. Do the stripping as follows:
(a) Clean the cooler to remove oil, grease, and dirt from the area to be
stripped. Refer to paragraph 4. D. Air Passage and External Surface
Cleaning.
(b) Use masking tape where coatings are to be kept. Use protective
caps and other fixtures and keep blasting material from becoming
trapped in cooler.
WARNING: WEAR PROTECTIVE CLOTHING AND EYE SHIELDS TO
PREVENT INJURY FROM BLASTING EQUIPMENT.
(c) Use any of the blasting media to blast exterior surface of the cooler.
Use the minimum pressure necessary to remove surface materials.
A pressure of 20 to 60 psig (137 to 414 kPa) is recommended.
Blasting time must not be longer than necessary to remove the
coating from the repair area.
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OTHER PERSONS.
(d) Use dry, oil-free compressed air at 20 to 30 psig
(137,9 to 206,8 kPa) to remove as much dust and loose
contaminants as possible. If sodium bicarbonate is used, rinse with
water and dry cooler with procedures in paragraph 4. D. (5) Oven
Drying.
(e) If this is the last cleaning step, preserve the internal oil passages.
Refer to the paragraph 4. H. Internal Oil Passage Preservation.
(2) Local Chemical Stripping. The following procedure can be done to remove
coatings from a localized area of the cooler. Replacement of the coatings
will be necessary after repair. Do the stripping as follows:
(a) Clean the cooler to remove oil and grease. Refer to paragraph 4. D.
Air Passage and External Surface Cleaning.
(b) Use masking tape where coatings are to be kept. Use protective
caps and other fixtures to keep blasting material from becoming
trapped in cooler.
FOLLOWING CHEMICAL. USE ONLY IN
(c) Apply brush-on paint stripper with a brush or swab to the area to be
stripped. When coating loosens wipe it off with a dry rag. Do this
process until the area is free of coatings.
(d) Flush the area with water to remove residual stripper.
OTHER PERSONS.
(e) Use dry, oil-free compressed air source at 20 to 30 psig
(137,9 to 206,8 kPa) to dry the cooler.
(3) Complete Immersion Stripping. The following procedure can be done to
fully remove the epoxy coating from exterior surfaces and air passages of
the cooler. Replacement of the coating will be necessary after repair. Do
the stripping as follows:
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CAUTION: IMMERSION STRIPPING WILL REMOVE ALL THE
PROTECTIVE COATING FROM THE EXTERIOR OF THE
COOLER. IT WILL BE NECESSARY TO REPLACE THIS
COATING AFTER CLEANING TO PROTECT THE
COOLER FROM CORROSION. FAILURE TO REPLACE
THE COATING WILL SEVERELY REDUCE THE SERVICE
LIFE OF THE COOLER.
(a) Install protective caps in the oil inlet and outlet ports to keep solvent
out of the oil passages.
(b) Put the cooler fully in immersion stripper heated to a temperature of
170 to 185°F (76,67 to 85°C) for two to three hours.
(c) When coating is dissolved and lifted from metal, remove the cooler
from the stripper solution. Turn the cooler upside down to let the
solvent drain.
(d) Steam clean exterior surfaces and air passages of the cooler. Refer
to the paragraph 4. D. (3) Steam Cleaning.
(e) Fully dry the cooler. Refer to the paragraph 4. D. (5) Oven Drying.
(f) Refer to the REPAIR section to replace the coating.
F. Internal Oil Passage Cleaning (If necessary)
(1) Particle Flush and Examination. The following procedure can be done to
clean the interior oil passages. It can be done before final testing of the
cooler and is also recommended for coolers where metal contamination is
suspected, to make sure the interior passages are clean. Flush and
examine the cooler as follows:
CAUSE BURNS.
(a) If the cooler is wet, oven dry cooler at 225 to 275°F (107,2 to 135°C)
for two hours minimum or until the cooler is fully dry.
(b) Install the cooler in a flushing and filtering setup, capable of giving
a flow of 25 gallons (95 liters) per minute. Refer to Figure 4.
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Typical Power Flushing and Filtering Setup

Figure 4
Page 22
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WARNING: FLUSHING SOLVENTS ARE COMBUSTIBLE AND CAN
CAUSE EYES, SKIN AND RESPIRATORY TRACT
PROBLEMS. USE IN A WELL-VENTILATED AREA. DO
NOT BREATHE THE VAPORS. DO NOT PERMIT THE
CHEMICALS TO TOUCH EYES OR SKIN. KEEP AWAY
FROM SPARKS AND FLAMES.
FOLLOWING CHEMICALS. USE ONLY IN
(c) Flush the cooler with flushing solvent or preservative oil while you
shake the cooler with mechanical shaker. Keep the flow for 15 to 20
minutes, then reverse flow for another 15 to 20 minutes. Flushing
can be improved by pulsing compressed air through the cooler.
(d) Install an inspection filter on outlet side and flush the cooler for five
minutes (minimum) in each direction. When you reverse the flush
flow, do not backflush the filter.
(e) Examine the filter for presence of particles. No particles that can be
seen with the unaided eye are permitted. If particles exist, do steps
(c) and (d) again until the particles are removed.
WARNING: FLUSHING SOLVENTS ARE COMBUSTIBLE AND CAN
CAUSE SKIN, EYE AND RESPIRATORY TRACT
PROBLEMS. USE IN AN AREA WITH A GOOD FLOW OF
AIR. DO NOT BREATH THE VAPOURS. DO NOT PERMIT
THE CHEMICALS TO TOUCH EYES OR SKIN. KEEP
AWAY FROM SPARKS AND FLAMES.
(f) Drain the flush solvent from the cooler.
OTHER PERSONS.
(g) Use a dry, oil-free compressed air source at 20 to 30 psig
(137,9 to 206,8 kPa) to remove as much solvent as possible from
inside the cooler.
(h) Preserve the internal oil passages. Refer to the paragraph
4. H. Internal Oil Passage Preservation.
G. Cooling Air Pressure Flow Test
(1) After you finish the cleaning, test the pressure flow of the cooler core to find
if the cooler has been fully cleaned. Refer to Figure 5. Do the pressure flow
test as follows:
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Pressure Flow Test Setup

Figure 5
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(a) Use air flow test adapter (2024585-1) to install the cooler in cooling
air side test setup. Do not install ducting on the air flow outlet side
of the cooler. Refer to Figure 5.
NOTE: Refer to Figure 6 for the pressure flow curve limits. These
limits are based on conditions with air inlet temperatures
of 65 to 75°F (18,3 to 24°C) at a barometric pressure of
29.92 in. HgA (760 mm HgA). Test conditions outside
these ranges can effect the test results. This procedure
has an air density correction factor to compensate for
extremes in test conditions. Refer to Figure 7, Sample
Test Record Sheet for compensation correction factor.
(b) Adjust the airflow through the measuring section, shown in Figure 5,
to a fixed value as shown on the chart in Figure 6.
NOTE: Refer to the measuring section of the Manufacturer’s
Instructions for procedures to get correct airflow rates.
(c) Measure the air inlet static pressure (P) in inches of water at the
cooler inlet. Record this reading as VALUE NO. 1 on the Test
Record Sheet. Refer to Figure 7, for a Sample Test Record Sheet.
(d) Measure the barometric pressure in inches of mercury absolute with
the barometer. Record this reading as VALUE NO. 2 on the Test
Record Sheet.
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Cooling Air Pressure Flow Limits

Figure 6
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Sample Test Record Sheet

Figure 7
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(e) Measure the temperature of the airflow with the thermocouple
meter. Record this reading as VALUE NO. 3 on the Test Record
Sheet.
(f) Do the cooling air side air density correction on the Test Record
Sheet, to find the corrected static inlet pressure (P) in inches of
water. Record the result on a Test Record Sheet.
(g) Compare the corrected static pressure (P) with the curve in
Figure 6. If the cooler passages are clean, the pressure will fall
within the ±20 percent band. If the pressure value is above the
band, the cooler air passages must be cleaned again. Refer to the
CLEANING section.
(h) Remove the cooler from the test setup.
(i) Preserve the internal oil passages. Refer to the paragraph
4. H. Internal Oil Passage Preservation.
H. Internal Oil Passage Preservation
(a) Fill the cooler with oil or preservative oil that has been strained
through a 10 micron filter, or finer.
(b) Turn the cooler over until all internal passages are coated with oil,
then drain the oil.
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5. CHECK
Table 6, can be used to examine the cooler.
Fluorescent penetrant unit Magnaflux, Division of ITW Inc

(Model ZA-28W) 3624 West Lake Avenue
Glenview, IL 60026-1215 (V37676)
Penetrant oil (SAE-AMS-2644) Customer furnished
B. Visual Checks
NOTE: Examine the parts in a clean area where there is good light. Use a
magnification glass if necessary.
(1) Examine the cooler for obvious damage such as cracks, punctures, dents
in the pans, ducts, and flanges for cracks. Examine the cooler surfaces for
distortion, burrs, corrosion, nicks, scratches, pitting.
(2) Examine the cooler core for bent or broken fins and flanges.
(3) Examine the cooler surfaces for damage to chemical film and epoxy
coating.
(4) Examine the detail parts for structural failure, damage, and wear.
(5) Examine threaded parts as follows:
(a) Look for crossed, stripped or broken threads. Discard parts which
have damaged threads.
(b) Examine threaded studs for looseness and thread condition. Refer
to the REPAIR section instructions if studs are loose or damaged.
(6) Examine all sealing surfaces and flanges for nicks, dents, and scratches.
Refer to the REPAIR section instructions if the sealing surfaces are
damaged.
C. Detailed Check Procedures
(1) Examine the ident plate (10, IPL Figure 1) to make sure that you can read
it, and to see if it is loose or damaged. Refer to the REPAIR section.
(2) Examine the nuts (15) and studs (20) for crossed, stripped or broken
threads. Replace the nuts and studs if they have damaged threads.
(3) Examine the screws (25) for crossed, stripped or broken threads. Replace
the screws if they have damaged threads.
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D. Non-destructive Examinations
NOTE: It is not necessary to do a penetrant examination on the cooler, unless
you find signs of cracks or physical damage during testing or physical
examination of the cooler.
(1) If there are visible fractures or cracks in the cooler, do a penetrant
examination to find the extent of the crack(s) as follows:
(a) Remove all rust, scale, burrs, dirt, grease and any other
contamination. Make sure the cooler is clean. Refer to the
CLEANING section.
WARNING: USE CORRECT PROTECTION. OIL USED DURING THIS
EXAMINATION CAN CAUSE SKIN, EYE, AND LUNG
DAMAGE. THE HOT BLACK LIGHT CAN CAUSE BURNS
TO BODY AREAS WITH NO PROTECTION.
(b) Use penetrant unit and penetrant oil in accordance with the unit
manufacturer’s instructions.
CAUTION: DO NOT PENETRANT ETCH COMPONENTS WITH
ANODIZE COATING. DAMAGE TO COATING WILL
RESULT.
(c) Do a liquid penetrant examination as given in ASTM E1417, method
A, B, or C, with examination materials to find the depth of cracks.
(d) Remove all penetrant oil when done. Refer to the CLEANING
section.
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6. REPAIR
Table 7, can be used to repair the cooler.
Abrasive cloth (ANSI B74.18, Grit No. 320) Customer furnished

(Aluminum oxide or silicon carbide)
Abrasive paper (ANSI B74.18, Grit No. 600) Customer furnished

(silicon carbide)
Chemical film (MIL-PRF-5541, Class 1A) Customer furnished
Cloth, lint-free Customer furnished
Compressed air or nitrogen source Customer furnished

(0 to 25 psig (0 to 172,5 kPa))
Epoxy ester coating Trail Chemical Corp

(X75351) 9904 Gridley Street
El Monte, CA 91731-1112 (V13054)
High Temperature Sealant:
Aluminum resin (WCA30, 400-mesh, 30-micron) S.L. Fusco Inc

1966 Via Arado
Compton, CA 90220-5924 (V7F252)
Curing agent (No. 550 hardener) Magnolia Plastics Inc

5547 Peachtree Industrial Blvd
Chamblee, GA 30341-2296 (V22121)
Epoxy resin (Shell Epon 828) Shell Chemical Co

A Div of Shell Oil Co
1 Shell Plaza, P.O. Box 2463
Houston, TX 77001 (V86961)
Milled fiberglass (731 ES 1/32 inch) Owens-Corning Fiberglas Corp

P.O. Box 382
Huntingdon, PA 16652-0382 (V21343)
Installation hand tool for captive screws Deutsch Fastener Corp

(H8603-10) El Segundo, CA 90245 (V08524)
Masking tape (SAE AMS-T-23397) Customer furnished
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Pressure gage (air) Customer furnished

(0 to 25 psig (0 to 172,5 kPa))
Sealing compound Customer furnished

(MIL-S-8802, Type II, Class B-2)
Solvent (Desoclean 45) PRC-Desoto International Inc

ASC-Los Angeles Div
5430 San Fernando Road
Glendale, CA 91203-1521 (V83574)
Safety water tank Customer furnished

(Sufficient size to fully submerge the cooler)
Toluene (TT-T-584) Customer furnished
Welding filler rod Customer furnished

(ER4043 or ER4047 per AWS A5.10)
Wire wheel or brush Customer furnished
Xylene (American Standards of Testing Customer furnished

and Materials ASTM D846)
SPECIAL TOOLS
Pressure test plug set Honeywell Ground Support Solutions

(2024572-1) 717 N. Bendix Drive
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B. General Repair Procedures
CAUTION: IN ORDER TO MAINTAIN THE ORIGINAL STRUCTURAL
INTEGRITY OF THE OIL COOLER, IT IS RECOMMENDED THAT
ONLY REPAIRS CONTAINED IN THIS COMPONENT
MAINTENANCE MANUAL BE ATTEMPTED. PAN
REPLACEMENT OR COMPLETE RECORE® ARE CRITICAL
REPAIRS THAT MUST BE PERFORMED USING SPECIAL
COMPONENTS, EQUIPMENT AND PROPRIETARY
ENGINEERING-CONTROLLED DATA AND PROCESSES
DEVELOPED BY HONEYWELL INTERNATIONAL, INC,
RECORE® IS PERFORMED IN ACCORDANCE WITH

HONEYWELL OVERHAUL REPAIR INSTRUCTIONS (ORI)
R00340. THIS ORI IS HONEYWELL PRORIETARY DATA AND
OBTAINING THIS INFORMATION (ORI R00340) MAY REQUIRE
AN EXPLICIT, SUPPLEMENTAL INTELLECTUAL PROPERTY
AGREEMENT BETWEEN HONEYWELL AND A REQUESTOR.
FOR OIL COOLERS THAT REQUIRE PAN REPLACEMENT OR

RECORE® UPGRADES, CONTACT:
HONEYWELL INTERNATIONAL, INC.

TELEPHONE: (800) 602-3099 (U.S.A.)
TELEPHONE: (602) 365-3099 (INTERNATIONAL)
FAX: (602) 365-3443
(1) Replace all damaged components that cannot be repaired.
(2) Use a thin flat bladed tool to gently straighten bent core fins. A small amount
of bend at the end of the fin will not effect the performance of the cooler.
(3) Use abrasive cloth or abrasive paper to remove corrosion, small nicks, and
scratches from the cooler.
(4) Apply chemical film (MIL-PRF-5541, Class 1A) to surfaces that show bare
aluminum. Brush apply chemical film to make sure area is fully covered.
(5) Refer to paragraph 6. F. Surface Finish Repair to touch-up epoxy ester
coating.
C. Detailed Repair Procedures
(1) If the ident plate (10, IPL Figure 1) is loose or damaged, replace it as
follows:
(a) Carefully file or grind the tack welds that attach the damaged ident
plate (10) to the welded assembly (30).
(b) Transcribe all necessary information from the old ident plate (10) to
the new ident plate.
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(c) Use a wire brush to clean all contamination from the areas to be
welded.
WARNING: READ AND OBEY ALL CAUTIONS, WARNINGS, AND
PROCEDURES IN THE APPLICABLE FEDERAL OR
MILITARY SPECIFICATION BEFORE YOU DO ANY
WELD OPERATIONS.
CAUTION: DURING WELDING OPERATION, DO NOT USE
PROLONGED APPLICATION OF HEAT TO THE COOLER
PANS. OVER EXPOSURE TO HEAT CAN CAUSE
SOFTENING OF PAN MATERIAL.
(d) Use filler rod to tack weld the four corners of the new ident plate (10)
to welded assembly (30).
(2) If the studs (20) in the welded assembly (30) are loose, missing or the
threads are damaged, remove and replace them as follows:
(a) Extract the pins that hold the stud (20) in place. Carefully remove
the stud (20) from the welded assembly (30).
(b) Install new stud (20) in the welded assembly (30). Refer
to MS51835.
(c) Install nuts (15) on the studs (20) finger tight only. Refer to the
ASSEMBLY section.
(3) If the screws (25) are loose, missing or the threads are damaged, remove
and replace them as follows:
(a) Use a 0.375 in. (9,525 mm) flat bottom drill to remove swage from
screw sleeve. Do not remove any parent material from cooler panel.
Refer to Figure 8.
WARNING: USE CORRECT PROTECTION. THIS
CHEMICAL/SOLUTION CAN CAUSE SKIN, EYE AND
RESPIRATORY DAMAGE. THE DANGER AND
PRECAUTIONS FOR EACH CHEMICAL IS DIFFERENT.
FOLLOW THE MANUFACTURER'S INSTRUCTIONS FOR
EACH CHEMICAL.
(b) Apply chemical film (MIL-PRF-5541, Class 1A) to flange surfaces
that show bare aluminum. Brush apply chemical film to make sure
area is fully covered.
(c) Apply a light coat of sealing compound to the contact surfaces of the
screw (25, IPL Figure 1) sleeve and cooler flange.
(d) Install new screw (25) on cooler flange as follows:
1 Insert new screw (25) through hole in cooler flange. Refer to

Figure 9.
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Screw Attachment Requirements

Figure 8
Screw Flare Procedures

Figure 9
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2 Use hand tool. Thread screw (25) into hand tool puller. The
screw must engage in the hand tool as far as possible until
end of screw sleeve makes contact with nose piece of hand
tool. Refer to Figure 9.
CAUTION: TOO MUCH FORCE MUST NOT BE USED.
DAMAGE TO SCREW (25, IPL FIGURE 1) AND
COOLER FLANGE CAN RESULT.
3 Squeeze the hand tool handles together firmly to flare the

screw sleeve. Excessive force is not necessary.
4 Loosen the screw (25) to remove the hand tool.
5 Examine the screw (25) for tightness and flare condition.
Refer to Figure 10.
6 If the screw (25) needs to be tighter, do steps 2 thru 4 again
and apply more force to the hand tool.
(e) Wipe unwanted sealing compound from around screw (25), cooler
flange and hand tool.
CAUSE BURNS.
(f) Let the sealing compound air dry for two hours at room temperature
then cure in an oven at 150°F (65,6°C) for five hours.
D. Structural Leak Repair
(1) Repair cracked weld seams and small punctures or cracks in the cooler
pans as follows:
(a) Refer to the CLEANING section to clean the interior and exterior of
the cooler of all oil and grease.
WARNING: USE SOLVENT AWAY FROM SPARKS AND FLAMES IN
AN AREA THAT HAS A GOOD FLOW OF AIR. DO NOT
BREATHE THE VAPORS. DO NOT LET THE SOLVENT
TOUCH YOUR EYES OR SKIN. THIS SOLVENT CAN
CAUSE BURNS AND LUNG DAMAGE.
(b) Use a clean wire wheel or brush to clean area to be welded of all
paint and contamination. Clean surface with a lint-free cloth
moistened with solvent.
WARNING: USE CORRECT PROTECTION. OIL USED FOR THIS
EXAMINATION CAN CAUSE SKIN, EYE AND LUNG
DAMAGE. THE HOT BLACK LIGHT CAN CAUSE BURNS
TO BODY AREA WITH NO PROTECTION.
(c) Do a liquid penetrant examination as given in ASTM E1417, method
A, B or C with inspection materials as given in SAE AMS 2644D, to
find the length of cracks.
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Screw Flare Requirements

Figure 10
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(d) If weld crack is not more than 2.0 in. (50,8 mm) in length, repair the
crack as follows:
CAUTION: WHEN STOP DRILLING, USE CARE NOT TO
DRILL INTO THE CORE ASSEMBLY. SEVERE
DAMAGE TO THE COOLER CAN RESULT.
1 Use a 0.1875 in. (4,7625 mm) diameter drill bit to stop drill a
hole at each end of the crack to a depth of 0.060 to 0.065 in.
(1,524 to 1,651 mm).
2 Use a rotary file to remove the fracture. The repair area must
have smooth slopes or contours to help in welding.
WARNING: READ AND OBEY ALL CAUTIONS, WARNINGS,
AND PROCEDURES IN THE APPLICABLE
FEDERAL OR MILITARY SPECIFICATION
BEFORE YOU DO ANY WELD OPERATIONS.
WARNING: DO ALL TIG WELDING IN ACCORDANCE WITH
AWS D17.1. DO ALL SPOT WELDING IN
ACCORDANCE WITH MIL-W-6858, CLASS B.
WEAR PROPER PROTECTIVE EQUIPMENT.
WELDING OPERATIONS CAUSE HEAT, AIR
BORNE METAL PARTICLES, FUMES, SLAG AND
DANGEROUS RADIATION.
CAUTION: DURING WELDING OPERATION, AVOID
PROLONGED APPLICATION OF TOO MUCH
HEAT TO COOLER PANS. OVEREXPOSURE TO
HEAT CAN CAUSE LEAKAGE OF THE COOLER
CORE.
CAUTION: DO NOT WELD ON THE COOLER CORE. HEAT
APPLIED TO THIS AREA CAN CAUSE DAMAGE
TO THE COOLER CORE.
CAUTION: WELDS REQUIRE FULL (100 PERCENT)
PENETRATION. FAILURE OF WELD COULD
OCCUR IF FULL PENETRATION IS NOT
REACHED.
3 Use filler rod to repair cracks by welding as instructed in

AWS D17.1, Class C. Welding is not permitted on the cooler
core face.
(e) Do a complete test of the cooler. Refer to the TESTING AND
FAULT ISOLATION section.
(f) Refer to paragraph 6. F. Surface Finish Repair, to apply chemical
film to repair area and touch-up epoxy ester coating.
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E. Core Leak Repair
(1) Pressurized Leak Check. The ability to repair core leaks is made by finding
the type and size of the leak and the location of the leak within the core.
Find the type and size of the core leak as follows:
(a) Use pressure test plug set (2024572-1) to seal the oil inlet and oil
outlet ports.
NOTE: If you use the facility air system, the air must be filtered to
remove oil, moisture and solid particles.
(b) Connect a regulated pressure source of room temperature air or
nitrogen to the pressure fitting of the plug set. Leave the cooling air
passages of the cooler open to ambient.
WARNING: BEFORE YOU APPLY PRESSURE TO THE COOLER,
MAKE SURE THAT ALL CONNECTIONS, HOSES, AND
TEST APPARATUS ARE CORRECTLY ATTACHED TO
PREVENT INJURY TO PERSONNEL WHEN COOLER IS
UNDER PRESSURE.
(c) Fill the safety water tank with enough water to fully submerge the
cooler. Put the cooler fully in water tank.
(d) Apply pressure to the cooler. Slowly increase the pressure to
25 psig (172,4 kPa) maximum and look for bubbles. If the cooler is
leaking, bubbles will show on the surface of the cooler core face.
(e) Slowly raise the cooler to the surface of the safety water tank and
listen for a change in volume of the leak. When the volume changes
the water level shows the depth of the core leak.
(f) Find if leakage from the cooler core is a feather leak or
medium-to-large core leak. A leak that shows small, "champagne"
size, air bubbles is a feather leak. Bubbles from internal core
leakage, much larger than a feather leak, shows a medium to large
leak in the core.
(g) Lower pressure to 10 to 20 psig (68,9 to 137,9 kPa).
(h) Locate and mark the air passages from which bubbles come from
with a grease pencil. Mark the depth of the leak on an adjacent side
plate.
(i) Decrease the air pressure to zero.
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OTHER PERSONS.
(j) Use a dry, oil-free compressed air source at 20 to 30 psig
(137,9 to 206,8 kPa) to remove as much water as possible from the
cooler.
(k) Remove the pressure test plugs from the oil inlet and outlets ports
of the cooler.
CAUSE BURNS.
(l) Dry the cooler (within 24 hours) in an oven at 225 to 275°F
(107,2 to 135°C) for two hours minimum, or until the cooler is fully
dry. Refer to procedures in the CLEANING section, paragraph 4. D.
(5) Oven Drying.
(2) Medium to Large Leak Repair. Medium to large leaks can be sealed as
follows:
NOTE: If you have both feather leaks and medium to large leaks, repair
medium to large leaks first.
(a) Prepare the cooler for core leak repair as follows:
CAUTION: NO MORE THAN TEN PERCENT OF TOTAL
SURFACE AREA OF CORE CAN BE REPAIRED
AS DESCRIBED HERE. FILLING MORE THAN
TEN PERCENT OF SURFACE AREA OF CORE
WITH REPAIR MATERIAL WILL DECREASE THE
PERFORMANCE CAPABILITY OF THE COOLER
TO BELOW PERMITTED LEVEL.
1 Use a pair of needle nose pliers or cutter tool, to remove or

compress fins as necessary to expose leaking area.
Compress fins just below the leak area. Refer to Figure 11.
NOTE: The core fin material can be folded or shaped to
keep adhesive from running down through the
core.
2 Do the procedures in paragraph 6. E. (1) Pressurized Leak

Check, again to make sure you have found the leak. You
must be able to see the leak.
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Core Leak Repair

Figure 11
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WARNING: BEFORE YOU APPLY PRESSURE TO THE
COOLER, MAKE SURE THAT ALL
CONNECTIONS, HOSES, AND TEST
APPARATUS ARE CORRECTLY ATTACHED TO
PREVENT INJURY TO PERSONNEL WHEN
COOLER IS UNDER PRESSURE.
3 Use compressed air at 20 to 30 psig (137,9 to 206,8 kPa) to

remove as much loose material as possible.
4 Make sure the cooler is clean. Refer to the CLEANING
section.
(b) Prepare the high temperature sealant (Shell Epon 828) as follows:
1 Mix 100 grams of epoxy resin (Shell Epon 828) and

140 grams of aluminum oxide to make component A.
2 Mix approximately 86 grams of curing agent and
approximately 139 grams of milled fiberglass to make
component B.
3 Mix component A with component B.
NOTE: Smaller quantities can be mixed with half the
amounts of components A and B. Sealant
compound has a maximum two day shelf life when
stored at room temperature.
(c) Apply the sealant (Shell Epon 828) compound to the cooler core
leak and cure compound as follows:
WARNING: USE CORRECT PROTECTION. HEATED PARTS
CAN CAUSE BURNS.
1 Put the cooler in an oven at a temperature of 225 to 275°F

(107,2 to 135°C) for two hours minimum, to heat the cooler.
2 Remove the cooler from the oven and put the cooler in a
horizontal position.
3 Use masking tape to mask off area around leak.
4 While the cooler is still hot, use a thin knife or small diameter
rod to apply sealant compound to leak area. Make sure that
sealant is applied directly on leak area or slightly below it so
that the entire leak area is well-covered with sealant.
NOTE: The core fin material can be folded or shaped to
keep adhesive from running down through the
core.
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WARNING: USE CORRECT PROTECTION. HEATED PARTS
CAN CAUSE BURNS.
5 Cure the sealant for one hour (minimum) at room

temperature, then cure at a temperature of 270 to 300°F
(132,2 to 148,9°C) for two hours minimum in an air
circulating oven.
6 Straighten the cooler flanges and bent core fins.
7 Test the cooler. Refer to the TESTING AND FAULT
ISOLATION section.
(3) Feather Leak Repair. Feather leaks can be sealed when you apply epoxy
ester coating to the exterior surfaces of the cooler. Interior cooling air
passages cannot be coated with more than two coats of epoxy, including
the original coating if cooler has not been stripped. Seal the feather leaks
as follows:
NOTE: If you have both feather leaks and medium-to-large leaks, repair
medium to large leaks first.
WARNING: EPOXY ESTER COATING IS FLAMMABLE AND CAN
CAUSE EYES, SKIN AND RESPIRATORY TRACT
PROBLEMS. USE IN A WELL-VENTILATED AREA. DO
NOT BREATHE THE VAPORS. DO NOT LET THE
CHEMICALS TOUCH EYES OR SKIN. KEEP AWAY FROM
SPARKS AND FLAMES.
(a) Prepare a tank of epoxy ester coating as specified in paragraph
6. F. Surface Finish Repair.
(b) Install pressure test plug set (2024572-1) on cooler oil inlet and
outlet ports.
(c) Immerse cooler in solution of epoxy enamel.
(d) Apply a vacuum of 22 in. (558,8 mm) Hg maximum to the internal oil
passages for one to two minutes while the cooler is in the coating
tank.
(e) Remove cooler from solution.
(f) Remove the pressure test plug set (2024572-1) from the oil inlet and
outlet ports and let the epoxy drain from the cooler.
(g) Cure epoxy coating as specified in paragraph 6. F. Surface Finish
Repair.
(h) Do the pressurized leakage check in step E. (1) again to find if leaks
are sealed.
F. Surface Finish Repair
(1) The cooler can be refinished only after removal of all old coating. If the
cooler has been stripped and is to be fully recoated, apply the epoxy ester
coating as follows:
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(a) Clean the cooler with procedures given in the paragraph 4. E. (3)
Complete Immersion Stripping.
(b) Brush-apply chemical film on all surfaces that show bare aluminum.
Make sure all the area is covered. Application of chemical film must
be as given in Military Specification MIL-PRF-5541, Class 1A.
(c) Make sure surfaces to be coated are fully dry and free from grease,
oil, dirt or any foreign matter that can inhibit curing or impair
adhesion of epoxy ester coating.
CAUTION: DO NOT LET EPOXY ESTER COATING ENTER THE
COOLER OIL INLET AND OUTLET PORTS AT ANY TIME.
INTERIOR OF COOLER MUST REMAIN FREE OF ALL
COATINGS.
(d) Use masking tape to cover the studs (20, IPL Figure 1), screws (25)
and oil inlet and outlet ports. The port flange faces do not need
epoxy ester coating. This is also done to keep coatings out of the
inside of the cooler.
(e) Prepare a tank of epoxy ester coating as follows:
WARNING: EPOXY ESTER COATING IS FLAMMABLE AND
CAN CAUSE EYES, SKIN AND RESPIRATORY
TRACT PROBLEMS. USE IN A
WELL-VENTILATED AREA. DO NOT BREATHE
THE VAPORS. DO NOT LET THE CHEMICALS
TOUCH EYES OR SKIN. KEEP AWAY FROM
SPARKS AND FLAMES.
1 Fill a safety water tank with epoxy ester coating that is large
enough to fully submerge the cooler.
2 Keep the resin solids content of tank at 9.0 to 13.0 percent
by weight. To increase resin solids content, add more epoxy
ester coating as necessary. To decrease the resin solids
content, add toluene or xylene.
3 Examine the viscosity of the solution in the tank on a regular
basis. Discard the material in the tank if the viscosity is more
than 15 centistokes maximum at 77°F (25°C).
(f) Put the cooler fully in the safety water tank of epoxy ester coating.
Shake or vibrate the cooler while in the tank to dislodge any air
bubbles.
(g) Remove the cooler from the tank and let it fully drain.
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OTHER PERSONS.
(h) Direct a stream of air at 20 to 30 psig (137,9 to 206,8 kPa) through
the cooling air inlet passages to assist runoff of unwanted solution.
External surfaces can be wiped free of runs, mars or defects with a
clean rag moist with solvent.
(i) Visually examine the coated surfaces for absence of film. Correctly
coated surfaces will give off a mirror-like gloss that is different from
uncoated surfaces. Recoat affected areas before you oven cure the
coating.
CAUSE BURNS.
(j) Let the cooler air-dry at room temperature for 15 to 30 minutes
before you handle it.
(k) Remove the masking tape from the cooler.
(l) To fully cure the epoxy ester coating, put the cooler in oven at a
temperature of 275 to 325°F (135 to 162,8°C) for 1-1/2 to 2-1/2
hours.
(m) Remove the cooler from the oven and let it return to room
temperature.
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7. ASSEMBLY (WITH STORAGE)
Table 8, can be used to assemble the cooler and prepare it for storage.
Barrier material (MIL-PRF-131) Customer furnished
Cloth, lint-free Customer furnished
Desiccant (MIL-D-3464) Customer furnished
Packing, o-ring Customer furnished

(M25988/1-017) (2 required)
Preservative oil Customer furnished

(MIL-PRF-23699 or MIL-PRF-8188)
Tape (UU-T-106) Customer furnished
SPECIAL TOOLS
Protective cover Honeywell Ground Support Solutions

(2372537-1) 717 N. Bendix Dr.
Protective cover Honeywell Ground Support Solutions

(2372538-1) 717 N. Bendix Dr.
Protective plugs Honeywell Ground Support Solutions

(2372732-1) (2 required) 717 N. Bendix Dr.
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B. Detailed Assembly Procedures
CAUTION: HANDLE THE COOLER WITH CARE. THE AIR INLET FLANGE
OF THE COOLER IS FRAGILE AND CAN BE EASILY BENT
UNDER THE COOLER WEIGHT. DO NOT USE THE INLET
FLANGE TO PICK UP THE COOLER. DAMAGE TO THE COOLER
CAN RESULT. TRANSPORT THE COOLER IN AN
APPROPRIATE PACKING CONTAINER.
CAUTION: DO NOT USE OLD PACKING. USE OF OLD PACKING CAN
CAUSE OIL LEAKAGE DURING VALVE OPERATION.
(1) Install nuts (15, IPL Figure 1) on studs (20) finger tight.
NOTE: Refer to the REPAIR section for the attachment of
ident plate (10).
C. Final Assembly Test
(1) Test the cooler. Refer to the TESTING AND FAULT ISOLATION section.
D. Storage Instructions
(1) Prepare the cooler for storage as follows:
(a) Clean the external surfaces with a clean, lint-free cloth.
WARNING: USE CORRECT PROTECTION IN AN AREA WITH A
GOOD FLOW OF AIR. PRESERVATIVE OIL CAN CAUSE
SKIN, EYE AND RESPIRATORY DAMAGE.
(b) Fill the cooler with oil or preservative oil that has been strained
through a 10 micron filter or finer. Turn the cooler over until all
internal passages are coated with oil, then drain the oil.
(c) Install protective plugs in cooler oil inlet and outlet ports.
(d) Install protective covers over the cooler air inlet and outlet ports.
Attach covers to cooler with tape.
(e) Wrap the cooler in pH neutral paper.
(f) Put cushioning material at the sharp corners to prevent damage to
the barrier material, and pack with a desiccant.
(2) Minimum storage conditions are as follows:
(a) Keep the cooler in an area away from high temperatures, dust,
moisture and corrosive fumes.
(b) Keep the cooler at a constant temperature below 100°F (37,78°C).
Do not permit the temperature to go higher than 125°F (51,67°C).
(c) Control the humidity to prevent moisture from collecting on the
cooler.
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8. SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
A. General
(1) Use the items shown in Table 9 to do procedures in this publication which
need special tools, fixtures, or equipment. The items can be procured from
Honeywell Ground Support Solutions, 717 N. Bendix Drive, South Bend, IN
46628-1000 unless otherwise stated.
Table 9. Special Tools, Fixtures, and Equipment
Nomenclature Use Part No.
Pressure test plug set Used to attach the oil inlet and outlet ports 2024572-1
to a source of high pressure air or nitrogen
during testing and cleaning.
Pressure drop tube set Used to attach the cooler oil inlet and outlet 2024573-1
ports to a source of heated oil during testing.
Used to attach the cooler to a source of
solvent to clean and flush the internal
passages during cleaning.
Air flow test adapter Used to measure the pressure drop across 2024585-1
the cooling air side of the cooler after cleaning.
Protective cover Used to cover oil cooler port during shipping and 2372537-1
storage.
Protective cover Used to cover oil cooler port during shipping and 2372538-1
storage.
Protective plugs Used to cover oil cooler port during shipping and 2372732-1
(2 required) storage.
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ILLUSTRATED PARTS LIST
1. Introduction
A. General
(1) The Detailed Parts List (DPL) gives a breakdown, in disassembly
sequence, of assemblies and detail parts that make up the unit identified in
this manual.
(2) The item numbers shown in the DPL are the same as the item numbers on
the exploded view illustration(s). To find a part number, find the part on the
illustration and write down the item number. Find the item number on the
DPL. The part number will be shown on the same line.
2. Explanation of Terms and Symbols
A. Non-procurable Items
(1) The notation (ORDER NHA) is used in the “NOMENCLATURE” column
when the part number listed is part of a matched set and can not be ordered
separately. The next higher assembly (NHA) is procurable and can be
ordered.
(2) The phrase “NONPROC” followed by a number is used in the “PART
NUMBER” column when there is no part number for the assembly.
NONPROC assemblies are not procurable and can not be ordered.
However, the detail parts of the assembly are procurable, and can be
ordered unless otherwise specified.
(3) The phrase “GAREF” or “TOREF” followed by an assigned number (for
example; GAREF118) is used in the “PART NUMBER” column when the
part number of the part is more than fifteen digits. The original part number
with more than fifteen digits is listed in the “NOMENCLATURE” column and
is the part number to be used when ordering the part.
(4) Parts that are deleted are identified in the nomenclature column as
“DELETED”. The part number will stay in the “PART NUMBER” column and
quantity will stay in the “UNITS PER ASSY” column. The nomenclature and
use code will be deleted.
(5) Parts that are superseded are identified in the “NOMENCLATURE” column
with the notation (SUPSD BY ITEM XXX). The superseding part is identified
in the “NOMENCLATURE” column with the notation
(SUPERSEDES ITEM XXX).
(6) Refer to Honeywell International, Inc., Torrance, California, Engineering
Standards Specification (ESS) Substitution List number ES1000-2 for
authorized substitutes to replace standard parts listed in the DPL.
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B. Interchangeability
(1) Superseded parts are not interchangeable with the superseding part(s).
The notation (SUPSD BY ITEM XXX) means that the part is not authorized
for continued use.
(2) When a part is replaced by another part and the notation (REPL BY ITEM
XXX) is used, the replacing part is newer and is more desirable than the
replaced part. However, either part can be used. The replacing part will be
identified with the notation (REPLACES ITEM XXX).
(3) Optional parts are identified with the notation (OPT TO ITEM XXX). The
optional part(s) will be entered following the part for which they are optional.
Optional part means that either part can be used and that neither part is
more desirable than the other.
(4) Refer to Honeywell International, Inc., Torrance, California, Engineering
Standards Specification (ESS) Substitution List number ES1000-2 for
authorized substitutes to replace standard parts listed in the DPL.
C. Effectivity (use) Codes
(1) The “EFFECT (USE) CODE” column sets the parts relationship with units
or assemblies which are essentially the same but have small variations.
These units or assemblies are the lead items on the DPL, and are given
reference letters such as A, B, C, D, etc. Parts which are not common to all
configurations, but are related to one or more of the coded lead items, carry
the letter(s) given to the lead item(s) to which they are related. The
effectivity column is blank if the parts are common to all lead items.
D. Units Per Assembly (quantity)
(1) The “UNITS PER ASSY” column shows the quantity of parts necessary to
assemble one next higher assembly. The letters “AR” in this column
indicate “as required,” and refer to bulk items or variable quantity items,
such as shims, spacers, or similar items. When items are listed for
reference purposes, the letters “RF” appear in the “UNITS PER ASSY”
column. These items, and their true quantities, are listed elsewhere.
E. Vendor Codes (VXXXXX)
(1) Vendor codes, preceded by the letter “V”, are listed in the
“NOMENCLATURE” column of the DPL to identify the manufacturer of
non-Honeywell International, Inc., Torrance, California, parts.
F. Specification Control Drawings
(1) When there is a Honeywell International, Inc., Torrance, California,
specification control drawing, the drawing number will be added in the
“NOMENCLATURE” column and identified as “(V70210 SPEC NO
XXX-XXX-XXXX)”.
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49-94-32
Apr 30/08
160564
G. Next Higher Assembly (NHA)

(1) The relationship of each listed item to its next higher assembly (NHA) is
shown by an indenture code. Each listed item is placed in the
“NOMENCLATURE” column one indenture (one dot) to the right of the
assembly to which it belongs. Items at equal indentures are all components
of a single assembly or subassembly. An example of the indenture code
system is shown below.
1 2 3 4 5 6 7
Assembly or Installation Descriptive Title
. Assembly
. Attaching Parts for Assembly
. . Detail Parts for Assembly
. . . Subassembly
. . . Attaching Parts for Subassembly
. . . . Detail Parts for Subassembly
. . . . . Sub-Subassembly
. . . . . Attaching Parts for Sub-Subassembly
. . . . . . Detail Parts for Sub-Subassembly
H. Attaching Parts
(1) Attaching parts are listed at the same indenture as the part they attach. The
symbols used to identify attaching parts are shown in the following sample:
. . CONNECTOR ASSY Listed part
. . ATTACHING PARTS Start of attaching parts
. . SCREW attaching part
. . WASHER attaching part
. . NUT attaching part
. . ***.*** End of attaching parts
I. Non-illustrated Items (-)
(1) Item numbers which do not appear on the illustration are identified by a
dash (-) preceding the item number.
(a) When two or more items which are visually alike are listed in
sequence, only the first item is illustrated. The illustration, however,
is applicable to all of the items.
(b) When components of an assembly or installation are separately
illustrated, the resulting assembly can be illustrated as an assembly
by bracketing the detail parts, and identifying the bracket as the
assembled unit. If brackets are not used, the detail parts are
illustrated, but the assembled unit is not.
J. Airline Stock No.
(1) The “AIRLINE STOCK NO.” column is for airline part numbers, and
accommodates eleven characters. This information is not supplied by
Honeywell.
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Apr 30/08
160564
K. Abbreviations
(1) Standard abbreviations used in the DPL agree with ASME Y14.38.
Non-standard abbreviations that spell words are not used.
L. Applicable Publications
(1) Assemblies which are referenced to their own Component Maintenance
Manuals are identified in the “NOMENCLATURE” column with a reference
to the ATA number of the applicable manual. These entries are also listed
in the INTRODUCTION section of the manual under Applicable
Publications.
M. Vendor Code List
(1) The vendor code list shows the vendor name, address and CAGE (if
applicable) for all vendors that are listed in the Illustrated Parts List. Refer
to Table 10 for Vendor Code List.
Table 10. Vendor Code List
Code Vendor
NOTE: The inclusion of vendor codes and part numbers in the DPL will not be construed as an
authorization for the vendor, pursuant to FAA regulations, to ship directly to the user.
Neither will it be construed as a certification by Honeywell that parts shipped by
vendors directly to users will conform to the type design, or that such parts are airworthy
or safe for installation.
V15653 Alcoa Global Fasteners, Alcoa Fastening Systems Div., Kaynar Products
800 S. College Blvd, Fullerton, CA 92831-3001
V70210 Honeywell International, Inc., 2525 W. 190th Street, Torrance, CA 90504-6002
V97928 Huck Intl Inc., 3969 Paramount Blvd, Lakewood, CA 90712-4193
3. Detailed Parts List (DPL)
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49-94-32
Apr 30/08
160564
Blank Page
Page 53
49-94-32
Apr 30/08
160564
.
Oil Cooler
IPL Figure 1
Page 54
49-94-32
Apr 30/08
160564
AIRLINE EFFECT UNITS

FIG. STOCK (USE) PER
ITEM PART NUMBER NO. 1 2 3 4 5 6 7 NOMENCLATURE CODE ASSY
1
- 1 160564-1 COOLER-OIL A RF
(INSTL OUTLINE)
(SERIES 1)
- 1A 160564-1 COOLER-OIL B RF
(INSTL OUTLINE)
(SERIES 2)
- 1B 160564-1 COOLER-OIL C RF
(INSTL OUTLINE)
(SERIES 3)
- 1C 160564-1 COOLER-OIL D RF
(INSTL OUTLINE)
(SERIES 4)
- 1D 160564-2 COOLER-OIL E RF
(INSTL OUTLINE)
(SERIES 3)
- 1E 160564-2 COOLER-OIL F RF
(INSTL OUTLINE)
(SERIES 4)
- 5 160565-1 . COOLER ASSY A 1
(NONPROCURABLE)
- 5A 160565-2 . COOLER ASSY B 1
(NONPROCURABLE)
- 5B 160565-4 . COOLER ASSY C 1
(NONPROCURABLE)
- 5C 160565-5 . COOLER ASSY D 1
(NONPROCURABLE)
- 5E 160565-8 . COOLER ASSY E 1
(NONPROCURABLE)
- 5F 160565-10 . COOLER ASSY F 1
(NONPROCURABLE)
10 2356796-1 . . PLATE-IDENTIFICATION 1
13 M25988-1-017 . . PACKING 2
-ITEM NOT ILLUSTRATED
Page 55
49-94-32
Apr 30/08
160564
AIRLINE EFFECT UNITS

FIG. STOCK (USE) PER
ITEM PART NUMBER NO. 1 2 3 4 5 6 7 NOMENCLATURE CODE ASSY
1
15 HW42-3 . . NUT-SELF-LOCKING 2
(V15653)
(V70210 SPEC NO
525-203-9006)
20 MS51833A201-7 . . STUD-KEY-LOCKED 2
25 HSG7900-3-4 . . SCREW-CAPTIVE 8
(V97928)
(V70210 SPEC NO
656-147-9105)
30 160565-3 . . WELDED ASSY A,B,C,E 1
(NONPROCURABLE)
(ORDER ITEM -1, -1A, -1B, -1D)
- 30A 160565-7 . . WELDED ASSY D 1
(NONPROCURABLE)
(ORDER ITEM -1C)
- 30B 160565-9 . . WELDED ASSY F 1
(NONPROCURABLE)
(ORDER ITEM -1E)
-ITEM NOT ILLUSTRATED
Page 56
49-94-32
Apr 30/08

CMM 49-94-32

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Honeywell International Inc.

2525 West 190th Street

TO: HOLDERS OF OIL COOLER COMPONENT MAINTENANCE MANUAL, 49-94-32, REVISION

COMPONENT PART NUMBER APU/ENGINE MODEL NO. AIRCRAFT APPLICATION

REVISION NUMBER 003 DATED 30 APRIL 2008

Page 9 Revised leakage repair instructions.

49-94-32 HIGHLIGHTS Page 1 of 2

PAGE HIGHLIGHTS (CONTINUED)

COMPONENT MAINTENANCE MANUAL

COMPONENT PART NUMBER APU/ENGINE MODEL NO. AIRCRAFT APPLICATION

49-94-32 Page T-1

49-94-32 Page T-2

©Honeywell International Inc. Do not copy without express permission of Honeywell.

Copyright 1996, 2008 Honeywell International Inc. All rights reserved.

Honeywell is a registered trademark of Honeywell International Inc.

49-94-32 Page T-3

©Honeywell International Inc. Do not copy without express permission of Honeywell.

49-94-32 Page T-4

©Honeywell International Inc. Do not copy without express permission of Honeywell.

WARNING: HONEYWELL ASSUMES NO RESPONSIBILITY FOR ANY HONEYWELL

INCORRECTLY REPAIRED COMPONENTS CAN AFFECT AIRWORTHINESS

RECORD OF TEMPORARY REVISIONS

SERVICE BULLETIN LIST

SPARE PARTS BULLETIN LIST

LIST OF EFFECTIVE PAGES

Title Page T-1 Apr 30/08 Testing and

Safety/Warranty/ Disassembly 11 Apr 30/08

LIST OF EFFECTIVE PAGES (CONTINUED)

Introduction ..................................................................................................................... INTRO-1

160564-1 1 A Qualification test unit. -

160564-1 2 B Added holes in weld assembly. -

160564-1 3 C Added black paint and epoxy coating. -

160564-1 4 D Machined flange. -

160564-2 3 E Added black paint and epoxy coating. 49-2376

160564-2 4 F Machined flange. 49-2376

VERIFIED SECTION VERIFICATION METHOD VERIFICATION DATE

Testing and Fault Isolation Verified by simulation Oct 10/96

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aluminum, air to oil

NOTE: Equipment/materials that meet or exceed given parameters can be used.

Compressed air or nitrogen source Customer furnished

Oil (MIL-PRF-7808 or MIL-PRF-23699) Customer furnished

Differential pressure gage (oil) Dresser Industries Instrument Div

Electric motor (for hydraulic pump) U.S. Electrical Motors

Hydraulic pump Roper Industries Inc

Oil heater/cooler Customer furnished

Pressure gage (air) Dresser Industries Instrument Div

Safety water tank Customer furnished

Shutoff valves Customer furnished

Thermocouple and electronic readout Newport Electronics Inc

Timer Customer furnished

Turbine flowmeter and electronic readout Flowmetrics Inc

Pressure test plug set Honeywell Ground Support Solutions

Pressure drop tube set Honeywell Ground Support Solutions

B. General Test Information

Proof Pressure and Leakage Test Setup

Oil Pressure Drop Test Setup

Trouble Probable Cause Correction

Proof Pressure and Leakage Test (Para. 2. C.)

Damaged cooler Replace cooler.

Leakage of manifold-to-core Open weld or seam Refer to the REPAIR section.

Oil Pressure Drop Test (Para. 2. D.)

Trouble Probable Cause Correction

Cleanliness Test (Para. 2. E.)

Pressure Flow Test (Refer to the CLEANING section)