Frequently Asked 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.

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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:        

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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.

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Yes. Dura-Lite’s products meet or exceed Original Equipment performance specifications.

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

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Dura-Lite™ currently manufactures hundreds of 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. Contact Dura-Lite™ Customer Support at 800-661-1117 if you are unable to find a Charge Air Cooler or Radiator Part # for your application.

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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.

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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.

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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.

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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.

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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.

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

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

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

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

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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”.

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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”.

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Yes. Dura-Lite’s warranty is not prorated and warrants the original vehicle installation for a period of 7 (seven) years or 1,000,000 (one million) miles or 1,609,000 (one million, six hundred and nine thousand) kilometres, whichever occurs first from the date of installation that its Evolution® Charge Air Coolers (the “CAC”) will remain within the allowable leak down rate specifications of the following applicable engine manufacturers under normal on-highway operating conditions: Caterpillar, Cummins, Detroit Diesel, International, Mack, Mercedes, Paccar, and Volvo (“Engine Manufacturers”).

Dura-Lite has maintained a less than 1% warranty return rate for more than 28 years. All products are tested to be 100% leak free before they leave the manufacturing facility.

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Most Dura-Lite Charge Air Coolers are backed by our industry leading (non-prorated) 7 Year / 1,000,000 Mile Warranty. Certain Part #'s carry a limited warranty ranging from 1 (one) to 3 (three) years depending upon the design and application. Distributors/ Dealers can visit Dura-Lite’s website Catalog for the applicable warranty coverage on each Dura-Lite Charge Air Cooler. If the Part # is not available, please contact Dura-Lite Customer Support at 800-661-1117 for the applicable Part # and warranty coverage.

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Yes. Dura-Lite Charge Air Coolers are warranted on the original vehicle installation for the length of the warranty period.

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Dura-Lite Charge Air Coolers are warranted on the original vehicle installation for the length of the warranty period.

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No. Dura-Lite Charge Air Coolers are designed to perform equal to or better than the Original Equipment Charge Air Cooler. Many Original Equipment Truck and Engine Manufacturers have selected Dura-Lite as their aftermarket supplier.

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Please reference Dura-Lite’s "Product Registration" section of the website to print off a PDF copy of the applicable form or contact Dura-Lite Customer Support at 800-661-1117.

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Complete and Mail or Fax the bottom portion of Product Registration (Warranty Card) that is attached to the new Dura-Lite product or register online on the "Product Registration" section of Dura-Lite’s website.

Address:   12012-44th St. S.E.
                  Calgary, Alberta T2Z 4A2
                  Canada

Fax:           403-206-7239

 

If you have any product questions or to submit a Warranty Claim, please contact Dura-Lite at:

Toll Free:     800-661-1117

E-Mail:

Support:      CustomerSupport@duralite.net

Warranty:    Warranty@duralite.net

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Please contact Dura-Lite Customer Support at 800-661-1117 with the Dura-Lite Part (Model) # and Serial # to have it checked.

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Open the hood or engine compartment of the vehicle and look for the Dura-Lite Part (Model) # and Serial # Label on the Charge Air Cooler. The Label is typically located on the top center of the Charge Air Cooler.

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Dura-Lite’s warranty is not prorated and warrants the original vehicle installation for a period of 1 (one) year from the date of installation (unlimited mileage). Eliminator® Charge Air Coolers (the “CAC”) will remain within the allowable leak down rate specifications of the following applicable engine manufacturers under normal operating conditions: Caterpillar, Cummins, Detroit Diesel, International, Mack, Mercedes, Paccar, and Volvo (“Engine Manufacturers”).

All products are tested to be 100% leak free before they leave the manufacturing facility.

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Dura-Lite’s warranty is not prorated and warrants the original vehicle installation for a period of 1 (one) year from the date of installation (unlimited mileage) that its Radiators (the “Radiator”) will remain free from defects in material and workmanship under normal on-highway operating conditions. Certain Part #'s are warranted for 2 (two) years depending upon the design and application. Distributors/ Dealers can visit Dura-Lite’s website Catalog for the applicable warranty coverage on each Dura-Lite Radiator. If the Part # is not available, please contact Dura-Lite Customer Support at 800-661-1117 for the applicable Part # and warranty coverage.

All products are tested to be 100% leak free before they leave the manufacturing facility.

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Dura-Lite's Tester-Kit™ is warranted against defects for a period of 1 (one) year from the date of purchase.

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No. A Charge Air Cooler should not be cleaned or re-used following a turbo failure. The Charge Air Cooler is often damaged by the event, and may cause further problems if re-used.

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No. A Dura-Lite™ Charge Air Cooler cannot be cleaned or re-used once it has been contaminated with oil.

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Dura-Lite™ recommends that a Charge Air Cooler should be tested every time the vehicle is in for service and/ or when the oil is changed. It is vital to the performance and reliability of the engine that leaks are detected as soon as possible in order to reduce problems caused by a leaking Charge Air Cooler.

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Dura-Lite™ estimates 40% of trucks 2 (two) years or older, have Charge Air Coolers that are leaking out of the engine manufacturers specifications.

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Dura-Lite™ manufactures a Test Kit that includes all of the tools and instructions necessary to test most models, makes, and/ or sizes of Charge Air Coolers safely and accurately. Please reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website or printed Catalog for additional information on the basic procedure. Dura-Lite’s Part # is “Tester-Kit™” and the kit is available through Dura-Lite™ Distributors/ Dealers. The Distributor/ Dealer will provide your cost. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

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Yes. Dura-Lite™ manufactures a Test Kit that includes all of the tools and instructions necessary to test most models, makes, and/ or sizes of Charge Air Coolers safely and accurately. Please reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website or printed Catalog for additional information on the basic procedure. Dura-Lite’s Part # is “Tester-Kit™” and the kit is available through Dura-Lite™ Distributors/ Dealers. The Distributor/ Dealer will provide your cost. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

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A leaking Charge Air Cooler results in incomplete combustion which causes; loss of engine power, increased fuel consumption, elevated soot levels in the oil, premature piston, ring, and valve failure, turbocharger failures, elevated coolant temperatures, and exhaust manifold failure.

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Yes. The rule of thumb is to pressure the Charge Air Cooler up to 30 psig and that it should hold air for at least 15 seconds. If there is a pressure loss of 5 psig or more within the 15 seconds, the Charge Air Cooler is leaking out of specification (Leak Down Rate Specification) and it should be replaced immediately. This is only a guideline and it is very important to check the engine manufacturers Leak Down Rate Specification (some common specifications are noted below). Please also reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website for additional information on the basic procedure.

Leak Down Rate Specifications:
 

Caterpillar 5 psig in 15 seconds @ 30 psig
Cummins (ISB, ISC, N14) 7 psig in 15 seconds @ 30 psig
Cummins (ISX, M11)  5 psig in 15 seconds @ 30 psig
Detroit Diesel 5 psig in 30 seconds @ 30 psig
International 5 psig in 15 seconds @ 30 psig
Mack 5 psig in 15 seconds @ 30 psig
Mercedes 5 psig in 15 seconds @ 25 psig
Volvo 5 psig in 15 seconds @ 30 psig

            

               

           

                

   

 

* psig (pound-force per square inch gauge)
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An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel an engine is wasting as a result of a Leaking Charge Air Cooler is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

* Please also reference Dura-Lite’s Leaking CAC Calculator page on the Website to find out what you can save!

Leaking Charge Air Cooler Cost:

 

Fuel Cost Calculator: Leaking 
Charge Air Cooler:
Dura-Lite™ 
Leak Free 
Charge Air Cooler:
   
Fuel Cost $2.25 $2.25 Per Gallon US Gallons
Fuel Economy 5.5 5.9 MPG (Estimate)  
Average Trip Per Day 600 600 Miles   
Consumption Per Day 109.1 101.7 Gallons US Gallons
Cost Per Day $245.45 $228.81     *   
* An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations. 
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Dura-Lite’s calculation of the amount of fuel an engine is wasting as a result of a Leaking Charge Air Cooler and an operator could save with a Dura-Lite™ Leak Free Charge Air Cooler is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

* Please also reference Dura-Lite’s Leaking CAC Calculator page on the Website to find out what you can save!

Dura-Lite™ Could Save An Operator:

 

Per Day* $17.00
Per Week* $85.00
Every 4 Weeks* $340.00
Per Year* $4,420.00
* An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations.
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An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel an engine is wasting is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

* Please also reference Dura-Lite’s Leaking CAC Calculator page on the Website to find out what you can save!

Dura-Lite™ Could Save A Fleet:

 

Number Of Vehicles: 50 100 250 500 750 1,000
Per Day* $17.00 $850.00 $1,700.00 $4,250.00 $8,500.00 $12,750.00 $17,000.00
Per Week* $85.00 $4,250.00 $8,500.00 $21,250.00 $42,500.00 $63,750.00 $85,000.00
Every 4 Weeks* $340.00 $17,000.00 $34,000.00 $85,000.00 $170,000.00 $255,000.00 $340,000.00
Per Year* $4,420.00 $221,000.00 $442,000.00 $1,105,000.00 $2,210,000.00 $3,315,000.00 $4,420,000.00
* An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations.
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Dura-Lite™ currently manufactures hundreds of 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. Contact Dura-Lite™ Customer Support at 800-661-1117 if you are unable to find a Charge Air Cooler or Radiator Part # for your application.

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Determine the Original Equipment Part # of the Charge Air Cooler on the vehicle. Distributor/ Dealers can then cross the Part # to a Dura-Lite™ Part # on Dura-Lite’s Website Catalog and/ or printed Catalog or contact Dura-Lite™ Customer Support at 800-661-1117 for further assistance.

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Open the hood or engine compartment of the vehicle and look for the Original Equipment Part # Label on the Charge Air Cooler. The Label is typically located on the top center of the Charge Air Cooler. If there isn’t a Label present, call your Dealer. Provide the vehicles V.I.N. to the Dealer and request the Original Equipment Charge Air Cooler Part #.

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Distributors/ Dealers can visit Dura-Lite’s Website Catalog. If the Part # is still not available, please contact Dura-Lite™ Customer Support at 800-661-1117 for further assistance.

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Contact Dura-Lite™ Customer Support at 800-661-1117 if you are unable to find a Charge Air Cooler or Radiator Part # for your application.

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With the exception of some specialty Original Equipment applications, Dura-Lite™ is not available as an Original Equipment option at this time. However, the vehicle owner can specify that the Dealer install a Dura-Lite™ Charge Air Cooler on the vehicle, prior to delivery.

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Dura-Lite™ sells its products through extensive distribution channels of Distributors/ Dealers. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

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Dura-Lite™ sells its products through extensive distribution channels of Distributors/ Dealers who will provide your product cost. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information.

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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.

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The price of Original Equipment Charge Air Coolers varies widely. Dura-Lite™ Charge Air Coolers are very competitively priced vs. the Original Equipment. Dura-Lite’s value is beyond the price and we offer an incomparable (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Charge Air Cooler Part #'s. The warranty is covered across North America.

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Dura-Lite™ products are available through extensive distribution channels of Distributors/ Dealers. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information. Orders received by 2:00 PM MST (Mountain Standard Time) for products in stock will be shipped the same day.

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Yes. Dura-Lite™ products are available through extensive distribution channels of Distributors/ Dealers. Same day and Next day service is available for most Charge Air Coolers and Radiators in North America. Please contact Dura-Lite™ Customer Support at 800-661-1117 for additional information.

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Dura-Lite™ currently manufactures hundreds of different Charge Air Coolers and we have an extensive inventory to support our product offering. Contact Dura-Lite™ Customer Support at 800-661-1117 if you are unable to find a Charge Air Cooler or Radiator Part # for your application.

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Contact Dura-Lite™ Customer Support at 800-661-1117 if you are unable to find a Charge Air Cooler or Radiator Part # for your application.

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Dura-Lite™ sells its Part # “Tester-Kit™” and other products through extensive distribution channels of Distributors/ Dealers. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information.

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Dura-Lite’s offers an incomparable (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Charge Air Cooler Part #'s. The warranty is covered across North America. Dura-Lite™ has a proven track record with more than 25 years of experience in the heat transfer business. Dura-Lite’s Charge Air Coolers lead the industry in both quality and durability, which allows them to outlast any other Charge Air Coolers in the marketplace today.

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It’s not possible to successfully repair a tube-to-header leak on a Charge Air Cooler and any repair made would simply be a temporary fix. At $2.25 per gallon, a leak free Dura-Lite™ Charge Air Cooler could save you $4,420.00 or more per year. Dura-Lite™ Charge Air Coolers have a (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Part #'s and the warranty is covered across North America.

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Dura-Lite™ manufactures the best Charge Air Coolers in the world, backed by the best warranty in the business with North American coverage. Other companies may advertise a longer warranty period, but the warranties are typically prorated with exceptions, exclusions and do not have North American coverage to support the product.

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Dura-Lite™ Evolution® Features:

* Where required, our product has been certified to EPA standards. The United States Environmental Protection Agency (EPA) program “Self-Certification of After-Market Parts” is aimed at allowing after market manufacturers of light-duty automotive parts to certify their products to EPA emission standards to ensure that using these parts to replace the Original Equipment parts will not result in adverse effect on the applicable vehicle emissions. Dura-Lite™ has taken the initiative to certify its product where applicable through this program. This involved extensive testing in accordance with EPA and SAE recommended test procedures. The test results were compared to Original Equipment Manufacturers data and EPA emission standards with favorable results. The implication of this certification is that, based on the test results, the effect on vehicle emissions, of using a Dura-Lite™ Charge Air Cooler in a truck will be the same as or better than using its Original Equipment Manufacturer counterpart.
  • Dura-Lite™ Patented Silicone Grommet Tube-To-Header Seal System allows the tubes to expand and contract in the grommet/ header. This eliminates the typical tube-to-header failure mode and resulting leakage.
  • Internally reinforced manifolds reduce side flexing and premature header/ manifold failure.
  • The Dura-Lite™ Offset Outer Fin design provides consistent performance by minimizing the build up of debris.
  • Manufactured leak free.
  • Engineered for performance, EPA Certified.*

Dura-Lite™ Evolution® Warranty:

* On most Charge Air Cooler Part #'s. Distributors/ Dealers can visit Dura-Lite’s Website Catalog and/ or printed Catalog for the applicable warranty coverage on each Dura-Lite™ Charge Air Cooler. If the Part # is not available, please contact Dura-Lite™ Customer Support at 800-661-1117 for the applicable Part # and warranty coverage.
  • The Evolution® features allow Dura-Lite™ to offer a (non-prorated) 7 Year / 1,000,000 Mile Warranty on most Charge Air Coolers.*
  • North American Warranty Coverage.
  • Less than 1% warranty return.

Dura-Lite™ Evolution® Benefits:

  • Continuous, consistent fuel economy.
  • Optimized power and emissions.
  • Reduced downtime.
  • Superior quality and warranty.
  • The most reliable Charge Air Cooler in the world.

Dura-Lite™ Channel Flow® Features:

  • Designed for (but not limited to) Agricultural and Industrial Applications.
  • Designed for applications where dust, dirt, and debris cause the outside of the Original Equipment Charge Air Cooler to become plugged up.
  • The Dura-Lite™ Channel Flow® Outer Fin design allows for smooth unobstructed airflow and makes cleaning fast and effortless.
  • Manufactured standard with Dura-Lite’s Patented Silicone Grommet Tube-To-Header Seal System and internally reinforced manifolds.
  • Production Part #’s for many Diesel Applications.

Dura-Lite™ Channel Flow ® Benefits:

  • Manufactured with the standard features incorporated in Dura-Lite’s Evolution® Charge Air Coolers.
  • Superior quality and 1 Year Warranty.
  • North American Warranty Coverage.
  • 0% Warranty returns to date.

Why Dura-Lite™ Charge Air Coolers:

* On most Charge Air Cooler Part #'s. Distributors/ Dealers can visit Dura-Lite’s Website Catalog and/ or printed Catalog for the applicable warranty coverage on each Dura-Lite™ Charge Air Cooler. If the Part # is not available, please contact Dura-Lite™ Customer Support at 800-661-1117 for the applicable Part # and warranty coverage.
  • All-Makes product coverage with over 600 production Part #’s for any diesel application. Additional Part #’s added continually.
  • Dura-Lite™ offers the best warranty in the business (non-prorated) 7 Year/ 1,000,000 Mile Warranty.*
  • Less than 1% failure rate.
  • North America Warranty Coverage.
  • Warranty backed by the factory.
  • No costly downtime.
  • Reduced overall fuel costs. A non-performing Charge Air Cooler will cost more in fuel. At $2.25 per gallon, a leak free Dura-Lite™ Charge Air Cooler could save you $4,420.00 or more per year.
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Dura-Lite™ Radiators:

  • Stronger fiber reinforced Tanks.
  • Heavier stronger Headers for unsurpassed durability.
  • Extra Header Stiffening Plate, eliminates the majority of leaks between the Tank and the Header.
  • Replacements for most applications.
  • Serving the Heavy Duty Truck, Transit Bus, Motorcoach, Motorhome, Industrial, Agricultural, Construction and Lift Truck markets.
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Please contact Dura-Lite™ Customer Support at 800-661-1117 to obtain an RGA (Returned Goods Authorization). A Charge Air Cooler core return will not be accepted by Dura-Lite™ without the Distributor/ Dealer first having obtained an RGA.

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