﻿GET_GEVOMechL2_03_01_01_121 - ANIMATION Screen
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Cast Water-Based Intercooler Core Installation 

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1. If required, install the cast WBIC core removal tool (TESCO T85373) onto the B-side (left side) of the locomotive.

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2. Install a lifting eye bolt to the new intercooler core on the A-side outer end fastening plate or the intercooler core end cover, if installed, and another lifting eye bolt on the B-side outer end fastening plate.

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3. Attach slings to the lifting eye bolts and carefully lift the core from the stable work surface.

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4. Place the intercooler core on the cast WBIC core removal tool (TESCO T85373), then remove the slings and lifting eye bolts from the sides of the core.

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5. Using the cast WBIC core removal tool (TESCO T85373), install the intercooler core into the radiator cab, sliding the core through the wing and into the intercooler shell.

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6. After the core is properly positioned in the intercooler shell, perform the following on the B-side (left side) of the locomotive:

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a. Remove the cast WBIC core removal tool (TESCO T85373).

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b. Install the outer end fastening plate with the 16, 1/2-inch hex bolts and washers, then torque to 55-62 lb.-ft. (75-84 Nm).

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c. Re-install the core access plate with end tank to the outer end fastening plate with a new O-ring and the 16 Allen bolts, then torque to 31-33 lb.-ft. (42-45 Nm).

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d. Re-install the vent fitting with a new gasket.

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e. Re-install the couplings to secure the piping to the intercooler on the B-side (left side).

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7. To the A-side (right side) of the locomotive:

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a. Re-install the outer end fastening plate and, if required, the intercooler core end cover using new O-rings as applicable.

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b. If required, secure the intercooler core end cover with the 16 Allen bolts, then torque to 31-33 lb.-ft. (42-45 Nm).

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c. Secure the outer end fastening plate to the shell using the 28, 3/8-inch hex bolts, then torque to 29.5 lb.-ft. (40 Nm).

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d. Re-attach the drain hose and fitting to the drain pipe.

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e. Close the access door.

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8. Refill the water to the cooling system.

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9. Visually inspect the intercooler and the associated piping for signs of leakage or damage.

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

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Cast Water-Based Intercooler Core Seals and O-Rings Inspection

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Inspect the intercooler core for signs of damage, including the core, water seals, and O-rings.

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If found, replace the applicable components, as necessary, in accordance with site specific locomotive maintenance instructions.

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If the water seals are damaged, corrosion will be found on the outside of the core.

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Clean the corrosion from the sides of the core using pressurized water. 

