﻿GET_GEVOMechL2_03_01_01_124 - ANIMATION Screen
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Fabricated Water-Based Intercooler Core Installation

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1. Ensure that the fabricated WBIC core is being installed by confirming the water inlet and outlet pipe outside diameter measurements are 3.5 inches (88.9 mm) and the B-side rectangular cover casing door is attached with hex bolts.

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2. If required, install the puller tool (PSB P5205) onto the B-side of the locomotive for installing the intercooler core.

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3. Install the four ½-inch lifting eye bolts on the intercooler core.

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4. Using a suitable lifting device, slowly lift the core and place it on the puller tool cradle, ensuring the core does not impact the side of the radiator cab while lifting.

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5. Using the attached puller tool puller bar and a 1/2-inch air ratchet with 3/4-inch socket, turn the worm gear and install the intercooler core in position in the radiator cab.

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6. After the intercooler core has been placed in the radiator cab, install the rectangular cover using the 20, 3/8-inch hex bolts, then torque the bolts to 22-24 lb.-ft. (30-33 Nm).

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7. Install the seal plate around the drain fitting using the four 3/8-inch hex bolts, then torque the bolts to 22-24 lb.-ft. (30-33 Nm).

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8. Install the two bolts and washers near the top of the cover, then torque the bolts to 110-120 lb.-ft. (149-163 Nm).

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9. Attach the drain hose and fitting, and close the access door.

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10. Remove and disassemble the puller tool (PSB P5205) from the B-side of the locomotive.

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11. Install the B-side access plate cover with a new air side O-ring.

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12. Torque the 10, 1/2-inch hex bolts to 55-62 lb.-ft. (75-84 Nm).

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13. Using new gaskets, re-install the Victaulic couplings that secure the piping to the intercooler on the B-side.

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14. Reconnect the vent fitting.

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15. Refill the cooling water system and visually inspect the intercooler and associated piping for signs of leakage or damage.

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16. Re-install the maintenance access panel underneath the wing of the radiator cab.

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Cast Water-Based Intercooler Core Removal

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1. Shut down the diesel engine.

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2. De-pressurize the cooling water system by holding the water fill assembly vent valve open for approximately one minute.

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3. Remove the maintenance access panel underneath the wing of the radiator cab, then set the panel aside and retain the hardware.

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4. Drain the water from the cooling system, below the level of the cast WBIC.

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5. From the A-side (right side) of the locomotive:

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a. Open, but do not remove, the access door.

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b. Remove the drain line and the fitting from the drain pipe.

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c. Remove the 28, 3/8-inch hex bolts from the outer end fastening plate that secures the intercooler core and attached end cover to the shell, and save all hardware for re-use.

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d. Remove the outer end fastening plate and discard the O-ring.

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6. From the B-side (left side) of the locomotive:

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a. Disassemble and remove the couplings securing the piping to the cast WBIC.

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b. Disconnect the vent fitting and discard the gaskets.

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c. Loosen and remove the 16 Allen bolts that secure the core access plate with end tank to the outer end fastening plate.

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d. Set the core access plate with end tank aside and save all hardware for re-use.

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e. Discard the O-ring.

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f. Loosen and remove the 16, 1/2-inch hex bolts and washers that secure the outer end fastening plate to the intercooler shell.

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g. Remove the outer end fastening plate and save all hardware for re-use.

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7. Install the cast WBIC core removal tool (TESCO T85373) onto the B-side (left side) of the locomotive and install the lifting eye bolt on the header plate.

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8. Install a lifting eye bolt on the B-side outer end fastening plate.

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9. Attach a sling to the B-side eye bolt to pull the core out from the radiator cab and onto the cast WBIC core removal tool (TESCO T85373).

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10. After the core has fully cleared the wing of the radiator cab and is stationary on the cast WBIC core removal tool (TESCO T85373), install the other lifting eye bolt on the A-side outer end fastening plate or the intercooler core end cover, if still installed.

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11. Attach lifting slings to the two eye bolts, then lift the core and place it on a stable (level) work surface.
