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Frequently Asked Questions - General Questions

Dura-Lite™ is a Customer Service driven company and we want to take every opportunity we can to talk to and help out our customers. We feel by having customers contact Dura-Lite™ Customer Support at 800-661-1117 we can serve them more effectively. We will not only offer information on the nearest Distributor/ Dealer, but will also help to source the product you are looking for.

You can contact us at:

Address:    12012-44th St. S.E.
                    Calgary, Alberta T2Z 4A2
                    Canada 
Tel:              403-259-2691
Toll Free:    800-661-1117
Fax:             403-252-2784
E-Mail:       

Dura-Lite™ has manufacturing facilities in North America, Australia, and Asia. The origin of a specific part can vary from time to time, dependent on demand and plant capacity. All production, regardless of the plant location, is built to Dura-Lite's specifications with Dura-Lite™ production staff.

Yes. Dura-Lite’s on-site state-of-the-art Test Facility is used to ensure products meet or exceed Original Equipment performance specifications and assure product durability.

Dura-Lite™ Evolution® Charge Air Coolers meet or exceed the Original Equipment performance specifications.

Dura-Lite™ currently manufactures over 600 different Charge Air Coolers for turbo-diesel powered equipment including (but not limited to) the following applications; Agricultural, Bus, Cement Mixers, Classes 2, 3, 4, 5, 6, 7, and 8 Trucks, Coach, Construction, Fire Trucks, Generators and Power Units, Government, Marine, Military, Motorhome, Off-Highway Vehicles, Oil Field, On-Highway Vehicles, Recreational, Refuse, Stationary, Transit, Vocational, and many others. Dura-Lite’s professionally certified engineers can also custom design a Charge Air Cooler, Radiator, and/ or Radiator/ Charge Air Cooler Cooling Module for any application.

No. Repairing a leaking Original Equipment style Charge Air Cooler is nothing more than a band-aid and it will end up costing you more in down time when it leaks again. If the original design wouldn’t last, how can a patch repair be expected to? The cost of a new Charge Air Cooler will ultimately be far less than the loss of fuel economy you will experience as the cooler leaks more each day. You also risk a potential turbo charger replacement as the turbo continues to work harder to compensate for a leaking Charge Air Cooler. In addition there is the potential for engine wear, and other issues associated with a leaking Charge Air Cooler.

No. Although there have been attempts to copy Dura-Lite’s design, Dura-Lite™ is the original inventor. Dura-Lite’s proven technology allows it to offer an industry leading (non-prorated) 7 Year/ 1,000,000 Mile Warranty on most Part #'s. Dura-Lite’s design and manufacturing process are protected under numerous patents. Companies offering imitation products are infringing on Dura-Lite’s patents and could be subject to legal action.

Dura-Lite™ refers to the seal between the tube-to-header joint as a grommet. The grommet allows the tubes to expand and contract in the grommet/ header, which eliminates the typical tube-to-header failure mode and resulting leakage.

No. The seal actually isn’t rubber, Dura-Lite™ uses a specially formulated high heat Patented Silicone Grommet Tube-To-Header Seal System. The silicone grommet allows the tubes to expand and contract in the grommet/ header, which eliminates the typical tube-to-header failure mode and resulting leakage. All Dura-Lite™ Charge Air Coolers are manufactured 100% leak free.

Yes, but only at Dura-Lite’s manufacturing facility. However, there should be no need to replace the grommets, as they are designed to last for the life of the Charge Air Cooler.

Dura-Lite Heat Transfer Products Ltd.™ is a Professional Engineering Company, certified by APEGGA (Association of Professional Engineers, Geologists, and Geophysicists of Alberta).

Dura-Lite™ maintains its technological lead in the industry by maintaining a staff of multi-disciplined engineers, utilizing some of the most advanced software and testing equipment available in the industry.

Capabilities:

  • 3D CAD (Computer Aided Design):
    • Mechanical CAD;
    • Design Validation;
    • Product Data Management;
    • Design Communication; and
    • CAD Productivity Tools.
       
  • CAD/ CAM (Computer Aided Design and Computer Aided Manufacturing):
    • Dura-Lite™ uses these tools to create faster production processes, components and tooling with dimensional accuracy.
    • After designing components in CAD software, the CAM tool is used by Dura-Lite™ to interface with and drive its CNC (Computer Numerical Control) machines to manufacture high quality parts.
  • FEA (Finite Element Analysis):
    • FEA software simulates the extreme conditions that Charge Air Coolers can be exposed to, without having to wait years for the results;
    • FEA can show weaknesses in designs, to allow improvements to be made before parts are manufactured and as a result, assures product durability; and
    • Once the FEA results have been analyzed and the design finalized, manufacturing can produce a prototype sample. The theoretical results can then be definitively confirmed with “actual” results in Dura-Lite’s Environmental Wind Tunnel Thermal Cycle Testing Equipment.
       
  • CFD (Computational Fluid Dynamics):
    • CFD software is used to simulate Charge Air Cooler airflow and thermal conditions to predict the performance of the design;
    • Theoretical analysis can be performed on a “virtual prototype”, allowing further design changes as required before the final design is completed and a Charge Air Cooler is manufactured; and
    • Once the CFD results have been analyzed and the design finalized, manufacturing can produce a prototype sample. The theoretical results can then be definitively confirmed with “actual” results in Dura-Lite's Environmental Wind Tunnel Performance Testing Equipment and/ or on a vehicle using the Chassis Dynamometer.
  • CMM (Coordinate Measuring Machine):
    • CMM equipment is used to measure the physical geometrical characteristics of the parts used in the manufacturing and assembly processes of Dura-Lite™ Charge Air Coolers. The measurements allow part and/ or assembly to be compared against the design intent;
    • Precisely recording the X, Y, and Z coordinates of a part, also allows points to be generated to construct features of a part when engineering new parts based on physical samples; and
    • Using this equipment allows Dura-Lite™ to ensure that our Charge Air Coolers are manufactured in accordance with the design specifications and to ensure fit and function in the application.
  • On-Site State-of-the-Art Test Facility:
    • Temperature controlled Environmental Wind Tunnel (EWT) and Chassis Dynamometer;
    • Performance and Thermal Cycle component testing equipment; and
    • Test equipment used to ensure products meet or exceed OE (Original Equipment) performance specifications and assure product durability.
  • Full capability to design and test custom Charge Air Coolers, Radiators and Radiator/ Charge Air Cooler Cooling Modules.

Please contact Dura-Lite™ Customer Support at 800-661-1117.

Round Tube™ is a trademark that Dura-Lite Heat Transfer Products Ltd.™ (“Dura-Lite”) uses for its 1st Generation Charge Air Coolers.

New Generation™ is a trademark that Dura-Lite Heat Transfer Products Ltd.™ (“Dura-Lite”) uses for its 2nd Generation Charge Air Coolers.

Ultimate Solution® is a registered trademark that Dura-Lite Heat Transfer Products Ltd.™ (“Dura-Lite”) uses for its 3rd Generation on-highway Charge Air Coolers.

Evolution® is a registered trademark that Dura-Lite Heat Transfer Products Ltd.™ (“Dura-Lite”) uses for its 4th Generation on-highway Charge Air Coolers. Where applicable, Dura-Lite™ Evolution® Charge Air Coolers have the Dura-Lite™ Part # prefix “US”.

Channel Flow® is a registered trademark that Dura-Lite Heat Transfer Products Ltd.™ (“Dura-Lite”) uses for its agricultural and industrial Charge Air Cooler applications. Where applicable, Dura-Lite™ Channel Flow® Charge Air Coolers have the Dura-Lite™ Part # prefix “AG”.