﻿GET_GEVOMechL2_05_01_01_82 - ANIMATION Screen
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Air-Based Intercooler Package Installation

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1. Attach a four-hook lifting device at the lifting points and lift the air-based intercooler package into place on the radiator cab.

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2. Align the mounting holes and install the four vertical mounting bolts on the radiator cab support wings on each side of the locomotive by accessing the bolts through the side screen openings.

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3. For side-mounted shutter assemblies, connect the air lines to the two shutter cylinders.

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4. For a top-mounted shutter assembly, connect the air lines to the shutter cylinders and install the shutter actuator cover.

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5. Connect the grease fittings at the connection points through the side screen at the front end on the engineer's side (A-side) of the locomotive.

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6. Connect the six wires to the correct “red apple” insulators on the helper's side (B-side) of the locomotive at the rear end of the inlet screen.

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7. Secure the wires to the tape rail on the radiator cab structure with fasteners.

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8. Using an appropriate lifting device, lift and install the return ducts to the IFE cover of the engine.

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9. Place the return ducts in the air-to-air frame and attach the return pipe brackets with fasteners that were removed during removal.

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10. Connect the return ducts to the top outboard connections of the air-based intercooler package.

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11. Connect the intermediate ducts at the lower "V" area of the air-based intercooler.

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12. Install the side screens on both sides of the locomotive.

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13. Install the top covers over the air-based intercooler package.

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14. With the air-based intercooler package installed, re-fill the locomotive cooling water system in preparation for returning the locomotive to service.

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Air-to-Air Heat Exchanger Removal

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1. Unbolt and remove the close off angles that secure the top of the air-to-air heat exchanger in place.

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

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3. 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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4. Using the lifting fixture, lift and slide the old air-to-air heat exchanger out of the sheet metal pocket support frame.

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Air-to-Air Heat Exchanger Installation

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

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Shutter Removal – Side-Mounted Shutter Assembly

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

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Shutter Installation – Side-Mounted Shutter Assembly

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1. Attach the lifting lugs to the shutter assembly and place the shutter assembly on the air-based intercooler frame.

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2. Install the four ½-13 x 1.25 inch hex bolts, ½ split lockwashers, and ½ flatwashers retained during removal.

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3. Install the ten ½-13 x 1.50 inch hex bolts, ½ split lockwashers, and ½ flatwashers retained during removal securing the air-to-air shutter assembly to the top of the air- based intercooler frame.

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4. If required, connect the air lines attached to the shutter cylinders on both shutter assemblies.
