﻿GET_GEVOMechL2_05_01_01_66 - STEP-BY-STEP Screen
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Typical steps to install one of the air-to-air heat exchangers to the air-based intercooler are as follows:

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<b>Warning: </b>To prevent personal injury and potential equipment damage, ensure that the engine cannot be started before removing, installing, or adjusting any engine component.

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Place the BS in the OFF position to prevent starting attempts.

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Also, place the FPB and the LCCB in the OFF position.

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Also, apply a warning tag on the EC switch.

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<b>Warning: </b>If the locomotive is equipped with AESS, the diesel engine may start without operator action.

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Exercise caution when working around the radiator cab.

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Ensure that AESS is disabled before performing any maintenance procedures on the locomotive.

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

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<b>Note: </b>The following steps are performed with the air-based intercooler removed from the locomotive and sitting on the ground on an appropriate support stand.

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<b>Warning: </b>All lifting fixtures and support stands referenced have been individually manufactured, tested, and certified.

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Lifting devices manufactured by other facilities per these recommended numbers should be individually tested and certified by an appropriate outside testing agency before use.

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Follow all Railroad Operating/Shop Procedures concerning lifting devices.

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1. Attach the lifting fixture (TESCO T65420) to the top of the air-to-air heat exchanger using all four tapped holes in the side rails of the heat exchanger.

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2. Using the lifting fixture, lift and slide the air-to-air heat exchanger into the sheet metal pocket support frame.

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3. Install the air-to-air heat exchanger shoulder and lower mounting bolts at all four corners of each heat exchanger.

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4. When re-installing the air-to-air heat exchanger on the air-based intercooler frame, only replace the two mounting bolts at the lower inlet air corner and leave out the mounting bolts at the other three remaining corners.

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<b>Note: </b>Replacing the two bolts at the lower inlet air corner only and leaving out the other three pairs of bolts allows for thermal growth of the intercooler cores.

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5. Install the close off angles that secure the top of the air-to-air heat exchanger in place.