Doc No.

DC16
500kva Scania DC16 Date: 28th Sept 2007
Cooling Package Maintenance
Page: 1 of 7
Aggreko International Directive
Status: Final

Objective:
Due to recent catastrophic failures of Scania DC16 engines in our fleet this document has been
created to highlight to all operational personnel the following:

¾ The Maintenance Improvements required.

¾ The fundamental differences between the Scania DC16 Cooling package and Cummins
KTA-19 cooling package.
¾ And explain the reason why the systems are different
¾ The serious damage that the engine can suffer due to poor radiator and after cooler
maintenance.
¾ Future Product Improvements

Maintenance Improvements Required:

The Scania DC16 engine cooling package has an engine driven cooling package with the after
cooler mounted above the main cooling radiator; both systems must be inspected separately with
a torch at each service visit for any sign of blockage.

If either requires to be cleaned they must be back flushed from the silencer compartment of the
container using a pressure washer and detergent until both cores are physically clean.

Care must be taken to make sure that both cores and the foam seal between the cores
are not physically damaged during this process!

¾ The Air to Air After cooler

¾ The Main Cooling Radiator

Prepared By: Approved By:

A. Methven Jack Denz
Rev A
Date 29/09

Technical Service and Support

 Doc No. DC16
500kva Scania DC16 Date: 28th Sept 2007
Cooling Package Maintenance
Page: 2 of 7
Aggreko International Directive
Status: Final

Very Dirty After cooler! Clean After cooler

Very Dirty Radiator! Clean Radiator

Prepared By: Approved By:

A. Methven Jack Denz
Rev A
Date 29/09

Technical Service and Support

 Doc No. DC16
500kva Scania DC16 Date: 28th Sept 2007
Cooling Package Maintenance
Page: 3 of 7
Aggreko International Directive
Status: Final

During the inspection of both cores the foam seal between the after cooler core and the Radiator
core must be inspected, if the seal is not intact the radiator must be removed for repair.

Seal in place

Seal Missing!

Ones both core have been cleaned a visual inspection of both cores must be made from the
engine compartment side of the cooling package and any debris removed from the cooling fan
duct.

Prepared By: Approved By:

A. Methven Jack Denz
Rev A
Date 29/09

Technical Service and Support

 Doc No. DC16
500kva Scania DC16 Date: 28th Sept 2007
Cooling Package Maintenance
Page: 4 of 7
Aggreko International Directive
Status: Final

Product History:

The major difference between the cooling packages on the Scania DC16 powered 500kva and the
KTA-19-G4 powered 500kva are as follows:

• The after cooler on the Scania DC16 engine uses and ATA (Air to Air) cooler package.

¾ Hot high Pressure Air from the turbo flows through the centre of the core and Cool low
pressure air from the engine driven fan flowing over the out side of the core to dissipate
the heat.

• The after cooler on the KTA-19-G4 engine uses a JWAC (Water to Air) cooler package.

¾ Hot high Pressure Air from the turbo flows over the outside of the core and the coolant
from the main cooling package flows through the centre of the core to dissipate the heat.

Scania DC16

Cummins KTA-19

Prepared By: Approved By:

A. Methven Jack Denz
Rev A
Date 29/09

Technical Service and Support

 Doc No. DC16
500kva Scania DC16 Date: 28th Sept 2007
Cooling Package Maintenance
Page: 5 of 7
Aggreko International Directive
Status: Final

Engine Technology:

The main reason for the machines having differently designed cooling packages is due the
emissions compliance of the Scania DC16 engine over the Cummins KTA-19 engine.

Emissionised engines require a high efficiency after cooler, hence the change to Air to Air after
cooling, they also incorporate the latest design of power cylinder.

The following information explains what effect poor cooling package maintenance will have on
both types of engine:

Cummins KTA-19-G4:

If the cooling package on this engine is not cleaned on a regular basis it will cause the engine
cooling temperature to increase, which in turn affects the after cooler efficiency and drives the
exhaust temperature up.

Prolonged running in this condition reduces the life of the power cylinder components and the
likely hood of increased “Hot” shutdowns of the engine.

With this engine being of older technology and utilising Standard Pistons (as shown below) with
conventional piston ring positioning within the power cylinder it was less susceptible to suffer any
damage during any “Hot” shutdowns.

Prepared By: Approved By:

A. Methven Jack Denz
Rev A
Date 29/09

Technical Service and Support

 Doc No. DC16
500kva Scania DC16 Date: 28th Sept 2007
Cooling Package Maintenance
Page: 6 of 7
Aggreko International Directive
Status: Final

Scania DC16:

If the cooling package on this engine is not cleaned on a regular basis it will cause the engine
cooling temperature to increase and /or the after cooler efficiency to drastically reduce causing
the inlet manifold temperature increase and drives the exhaust temperature up.

Prolonged running in this condition reduces the life of the power cylinder components and the
likely hood of increased “Hot” shutdowns of the engine.

With this engine being of the latest technology and utilising Articulated Pistons (as shown below)
which are made up of an ductile iron crown and an aluminium skirt with reduced air space piston
ring positioning in the power cylinder it is proving to be very susceptible to suffer from piston
scuffing during these “Hot” shutdowns.

Piston Scuffing

Prepared By: Approved By:

A. Methven Jack Denz
Rev A
Date 29/09

Technical Service and Support

 Doc No. DC16
500kva Scania DC16 Date: 28th Sept 2007
Cooling Package Maintenance
Page: 7 of 7
Aggreko International Directive
Status: Final

Future Product Improvements:

¾ Pending release of a Mo6 to install cooling level protection on all Scania

powered equipment in our fleet.
¾ All new equipment built by Aggreko Manufacturing after DEC07 will have the
level sensor fitted.
¾ Improved engine protection program file being developed by Dief to protect the
DC16 engine.
¾ The possibility of future campaign on DC16 water pumps.

Prepared By: Approved By:

A. Methven Jack Denz
Rev A
Date 29/09

Technical Service and Support