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<b>Note:</b> This demonstration displays the steps to install a cast WBIC core.

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For details of installing a fabricated WBIC core, refer to the Fabricated WBIC Core Installation section of this module.

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Typical steps to install the cast WBIC core are as follows:

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<b>Warning:</b> The approximate nominal weight of the cast WBIC core is 1428 lbs. (648 kg) and the approximate dry core weight is 518 lbs. (235 kg).

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Ensure that the lifting device, cables, and straps are adequate.

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Failure to do so may result in personal injury or death.

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<b>Caution:</b> While lifting the core, ensure that the movement of the core is away from the radiator cab.

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Do not simply lift the core straight up.

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Failure to do so may result in damage to the components.

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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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<b>Note:</b> Depending on the cast WBIC B-side end plate design, M10 bolts either with or without hard lock (Nord-Lock) washers may have been used instead of Allen bolts to secure the core access plate with end tank to the outer end fastening plate.

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If so, install and torque the M10 bolts with hard washers to 36 lb.-ft. (49 Nm) or, for M10 bolts without hard washers, to 31 lb.-ft. (42 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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<b>Note:</b> For additional information on assembly and installation of the Victaulic couplings, refer to the Victaulic Coupling Installation section of this module.