﻿GET_GEVOMechL2_05_01_01_67 - STEP-BY-STEP Screen
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There are two different generations of the air-to-air shutter assembly designs; a top-mounted design and a side-mounted design.

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The removal of a side-mounted shutter assembly is explained in this section.

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Typical steps to remove a side-mounted shutter assembly from 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>Not all Evolution Series locomotives are equipped with the air-to-air shutter assembly.

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Some, in place of the air-to-air shutter assembly, have a covering grate.

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For these locomotives, remove all sets of clamps, lockwashers, washers, and bolts that secure the grate to the assembly.

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<b>Note: </b>The following steps are performed with the air-based intercooler removed from the locomotive and sitting on a 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 Procedures concerning lifting devices.

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1. If required, disconnect the air lines attached to the shutter cylinders on both shutter assemblies.

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2. Loosen the ten ½-13 x 1.50-inch hex bolts that secure the air-to-air shutter assembly to the air-based intercooler frame.

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3. Loosen the four ½-13 x 1.25-inch hex bolts that secure the air-to-air shutter assembly to the air-based intercooler heat exchanger.

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4. Remove and save the top two ½-13 x 1.50-inch hex bolts, split lockwashers, and flatwashers, then attach swivel clevis lifting lugs in the bolt holes.

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<b>Warning: </b>The air-to-air shutter assembly weighs approximately 225 lbs. (102 kg).

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With the lifting device connected to the swivel clevis lifting lugs, ensure the lifting device is adequately supporting the assembly weight before removing the remaining hardware.

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

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5. With the air-to-air shutter assembly properly supported, remove and save all previously loosened hex bolts, split lockwashers, and flatwashers.

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6. Once all the bolts have been removed and the shutter assembly is supported by the lifting lugs, support the bottom of the shutter so it does not swing out as the support stand is removed.

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<b>Note: </b>The shutter assembly may also be supported by sitting on the forks of a fork lift as well to ensure it is secure.

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7. Remove the shutter assembly from the air-based intercooler frame.