SALE!! 10% OFF DNP THROUGH 12/30/16
AV-TEKK CHARGE- AIR COOLERS AND GRIZZLY AIR EGR’S
Av-Tekk has grown to offer the best heavy duty charge-air coolers on
the market, top of the line remanufactured EGR and oil coolers, and
Av-Tekk’s very own quick check leak test kit.

Promotion details:
• Order using DCS to receive the discount
• Part #’s carry over with “AV-” prefix
• Contact your Hino DPM with questions
• Order 6 + Charge Air Coolers or EGR’s and receive FREE freight (see QR guide for
standard freight policy)
• 7 yr. unlimited miles warranty on all new HD Charge-Air Coolers
• Mix and Match of Av-Tekk and Grizzly Air products is allowed
• Quest for the Cup and Added Rewards at 1% applies

• Sale Price expires 12/30/16
Av-Tekk website:

http://www.avtekk.com/index.html

TO:
Dealer Principals
Parts Managers
General Managers
Parts Sales
BULLETIN: PA-2016-083
NOW
DATE:
EXP:
12/30/16

Hino Trucks reserves the
right to make changes,
including change in price,
content, description,
terms, time period, etc. at
any time without notice.

Hino Trucks National PDC
Phone: (866) 372-4466 | Fax: (662) 342-5151
E-Mail: helpdesk@hino.com

Av-Tekk

Supplier:
Supplier Information

Av-Tekk Charge-Air Coolers is a leading supplier of Charge-Air Coolers and product of a family business that was founded in 1950, Diesel
USA Group. Av-Tekk's heavy-duty charge-air coolers (the bar and plate charge-air cooler) has quickly grown in popularity in the chargeair cooler industry. Av-Tekk also offers Grizzly Air Products an Innovative engine solution brand offering EGR Coolers.

Customer Service &
Technical Support

Hino Parts Support Phone: 866-372-4466
Hino Parts Support Email: helpdesk@hino.com
Hino Parts Support Fax: 662-342-3939
Av-Tekk Charge Air Coolers Phone: 877-288-3551
Av-Tekk Charge Air Coolers Email: [email protected]
Av-Tekk Charge Air Coolers Web: www.Avtekk.com
Av-Tekk Charge Air Coolers Fax: 800-933-3432

Order Procedures:

All orders are to be placed through the Hino Dealer Connect System (DCS). For special orders or for customer support contact Supplier
directly via phone number.

Stock Orders

Emergency Orders
Minimum Order
Quantity
Freight Policy:

Enter orders in DCS Screen DC202 under Sales Type “S”. All direct ship (DS Orders) items will be shipped from a local Supplier PDC.
Emergency orders (EM) may be entered into DCS screen DC202 as a Sales Type “E” or "V". All emergency orders will be processed with a
“rush” order. Freight and Handling fees will be identified on the Hino invoice.
No minimum quantity
All orders less than 6 units is billed to ordering dealer. Please see freight index for individaul unit freight cost.
Av-Tekk - Charge Air Coolers

Grizzly Air - EGR

Free Freight Policy:

Orders of 6 or more will received prepaid freight. Mix and Match is allowed. Ie. Av-Tekk & Grizzly Air products.

Order Fulfillment
Policy:

The standard order processing time is 2 days from date of order placement.

Part Number Pricing:

Pricing will be available on-line in the Hino DCS system. In addition, the prices will be forwarded to your service bureaus within two weeks
of each pricing update.

Format:

Standard Part numbers are Pre-fixed with "AV-" & all spaces have been removed.

Mega Fleet:

All-Makes parts are not included in the Hino Mega Fleet pricing file but should be sold to Mega Fleet customers and filed as Miscellaneous
Items in Corcentric when submitting for reimbursement.

Warranty:

Please see the Av-Tekk and Grizzly Air Specific warranty documents. Warranty is handled directly with the vendor.

Returns:

Contact Supplier directly to obtain a Return Goods Authorization code by phone number or email address listed above. All returned items
MUST have prior approval and the Return Goods Authorization (RGA) marked on the outside of the box. RGAs have an expiration date of
sixty (60) days; after sixty (60) days the return will become null and void. Will not authorize any returns that are not properly packaged or in
the original packaging. No credit will be issued for product that has been damaged, altered, or installed on equipment. The customer is
responsible for all freight charges on the returned merchandise. Special order items or non stock items are not returnable.

Shipping Inspection
and Damaged
Product:

All merchandise should be inspected upon arrival and carrier damage claims should be filed with the carrier immediately. We are not
responsible for, nor are we in a position to make a claim after the freight carrier accepts the shipment from us. For excess stock returns,
contact the Supplier directly.

Supplier Cross
Reference Web Site:

www.avtekk.com

Conclusion:

Av-Tekk Brand HD Charge Air Coolers are 100% brand new. High efficiency and durable Bar & Plate design. Bar & Plate design increases
the life of your charge-air cooler when compared to Tube and Fin designs. Av-Tekks highly efficient durable cooler design eliminates the
header plates in the construction process. Whether it’s a personal vehicle or a work vehicle, from light duty to heavy duty engines GrizzlyAir offers a wide range of EGR and Oil Cooling products

PA-2015-014
2.11.15

product catalog

new inside:

2015 - 2016

product guide
Av-Tekk New and new hd
Available in many High Volume applications
• High efficiency and durable Cooler Designs
• Heavy Duty Bar & Plate options along with OE Style
Tube & Fin designs
• Industry Leading Charge-Air Coolers.
• NEW! Seven-Year Warranty - Unlimited Miles (Bar & Plate)
Two-Year Warranty (Tube & Fin)
Hose & clamp kits
• Order corresponding kit part number to
get everything you need to replace
ALL hosing for the charge-air cooler.
• Both hoses contained in Kits are
hot side compatible.
quick check leak test kits
• No other special tools needed
• Quickest and easiest connections available
• Simulates a constant air load for
accurate diagnostics
• Fits most charge air cooler connection types
• Relief valve and restraints for safety
• Includes compact carrying case
grizzly air egr coolers and oil coolers
Available in many High Volume applications
• Improved designs to help eliminate common issues related to
EGR and Oil coolers
• Superior quality when compared to other remanufactured units in the
market today
• 12 month - Unlimited Mileage Warranty on most products
Lifetime Warranty - Unlimited Mileage Warranty on products
where designated
• Available for Ford – Dodge – GMC – Chevrolet – International Mercedes Benz and Cummins Engines

Table of Contents
Item

Page Number

Get to Know Your CharGe-air Cooler ................................................................................................ 2
SavinG MoneY with av-teKK ....................................................................................................................... 3
av-teKK new hD ................................................................................................................................................. 3
tYpiCal tube & Fin ........................................................................................................................................... 3
QuiCK CheCK aDvantaGeS ............................................................................................................................ 4
av-teKK hoSe & ClaMp KitS.......................................................................................................................... 5
eGr CoolerS ....................................................................................................................................................... 6
oeM part nuMber CroSS reFerenCe ....................................................................................................... 7
Cooler DiMenSional DrawinGS .............................................................................................................. 13
aDvanCe MiXer................................................................................................................................................ 13
Chevrolet ........................................................................................................................................................ 13
DoDGe truCK .................................................................................................................................................... 13
FleXliner ........................................................................................................................................................... 14
ForD ...................................................................................................................................................................... 14
FreiGhtliner .................................................................................................................................................... 15
GilliG buS .......................................................................................................................................................... 17
international/naviStar ............................................................................................................................ 17
Kenworth .......................................................................................................................................................... 19
MaCK..................................................................................................................................................................... 20
peterbilt ............................................................................................................................................................ 22
volvo/GMC/white ........................................................................................................................................... 23
weStern Star ................................................................................................................................................... 24
oeM eGr part nuMber CroSS reFerenCe ............................................................................................ 25
GriZZlY air eGr CoolerS / oil CoolerS ............................................................................................... 26
CuMMinS: DoDGe - ForD - SterlinG......................................................................................................... 26
Detroit................................................................................................................................................................ 29
ForD ...................................................................................................................................................................... 29
General MotorS ............................................................................................................................................ 37
MerCeDeS benZ ................................................................................................................................................ 38
naviStar ............................................................................................................................................................. 39
volvo ................................................................................................................................................................... 44
av-teKK warrantY ........................................................................................................................................ 45
GriZZlY air warrantY ................................................................................................................................. 46
OEM Charge-Air Cooler Cross Reference

EGR Cooler Cross Reference

aDvanCe MiXer....................................................... 7
blue birD................................................................... 7
Chevrolet/GMC/General .................................. 7
DoDGe truCK ........................................................... 7
FleXliner .................................................................. 7
ForD/SterlinG ........................................................ 7
FreiGhtliner ........................................................... 8
GilliG buS ................................................................. 9
international/naviStar ................................... 9
Kenworth ............................................................... 10
MaCK.......................................................................... 10
MarMon MotorS ..................................................11
peterbilt ..................................................................11
volvo/ GMC/ white .............................................. 12
weStern Star ........................................................ 12

CuMMinS enGineS ................................................ 25
Detroit enGineS .................................................. 25
ForD enGineS ......................................................... 25
General MotorS enGineS ............................... 25
MerCeDeS enGineS .............................................. 25
naviStar enGineS ................................................ 25
volvo enGineS ...................................................... 25

Get To Know Your Charge-Air Cooler
today, charge-air coolers are used on virtually every heavy-duty truck. they are essential to meet engine
manufacturers’ design objectives for horsepower, fuel economy, and exhaust emissions.
the trend toward smaller sized engines producing higher horsepower places increased stress on critical performance
components such as turbochargers and charge-air coolers. boost pressures have driven cooler inlet temperatures
from around 325°F during the 70’s and 80’s, to over 400°F in later
model engines.
a typical cooler operating with slightly over 400°F inlet temperature will drop the boosted air’s temperature to just
over 100°F before it enters the engine. this drop of nearly 300°F causes extreme thermal stresses from expansion
and contraction of the entire structure. these stresses along with engine load variances and chassis vibrations cause
frequent fatigue failures, the majority being cracked header plates and air tubes (see image below).

CRACKED HEADER PLATES

AIR TUBE CRACKS

Understanding Your Service Options:

2

“FIX AND GO”

“rePLACe & reWeLD”

“Av-Tekk NeW & NeW HD”

Putty type fix at a radiator
repair shop is not durable and
often leads to wasted time and
money. it does not strengthen
weak areas that will eventually
fail when placed back
in service.

Complete replacement of the
center section or “brick” is
good but very expensive and
is subject to the quality of the
replacement brick

av-tekk’s new and new
hD units require no core and
both offer superior quality
and performance. these
completely new replacement
coolers are available in several
high volume applications.

LOW COST/LOW QUALITY

HIGH COST/HIGH QUALITY

LOW COST/HIGH QUALITY

NOT COMMERCIALLY
ACCEPTABLE!

OK SOLUTION!

BEST SOLUTION!

Saving Money with Av-Tekk
the av-tekk brand means av-tekk solutions. our brand has been revolutionizing the charge-air cooler industry
since the very beginning. we have made it our mission to improve the durability and experience of all diesel
charge-air coolers. From the introduction of the only Faa approved rebuild process for charge-air coolers, to
our amazing heavy duty bar and plate designs, av-tekk is constantly working to improve our brand through the
quality of products we provide. even now when the industry is asking more of its diesel charge-air coolers, avtekk’s products stand above the rest.

Typical Tube & Fin

Av-Tekk New HD

Our “Heavy-Duty” bar and plate construction, denoted by “HD” on the part number suffix, is the most
rugged and durable type of construction and is backed by our 7-year/unlimited mileage warranty. the
“hD” coolers are available on most popular applications where experience has shown they are needed.

• Industry’s Best Charge-Air Coolers

• Broadest Service Network

• Nation Leading Warranty

• Priced Right for Highest Value
av-tekk’s hD design uses a series of heavy
bars and plates to form a stronger cooler and
eliminate the header plate and the fragile
air tubes permitting the manifolds to be welded
directly to the bars in the construction process.
Industry studies have shown header plate thermal fatigue
failures and air tube leaks account for the majority of
charge-air cooler failures.

Example of Tube & Fin
construction using a header
plate, typical of most
OEM designs.
Example of Av-Tekk’s
Heavy Duty Bar & Plate
Construction Design

3

Are you testing coolers to see if they are
leaking beyond O.E.M. specifications?

Quick Check Advantages
• No other special tools needed
• Quickest and easiest connections available
• Simulates a constant air load for
accurate diagnostics
• Fits most charge air cooler connection types
• Relief valve and restraints for safety
• Includes compact carrying case

THIS COMPLETE KIT COMES WITH
ALL ADAPTERS AND FITTINGS TO
TEST ALL TRUCK SIZES, PICKUPS
THRU CLASS 8 TRACTORS.
ORDER PART NUMBER A351CAS

For More on Quick Check leak test Kit Go online to: www.av-tekk.com
Av-Tekk’s new Test Kit may be used to test the pressure
drop of most known sizes of charge-air coolers (C AC).
According to most O.E. Manufacturer’s Specifications,
charge-air coolers that show a static pressure drop greater
than 5 PSI in a 15 second test, beginning at 30 PSI, should
be replaced. Av-Tekk’s new CAC Test Kit provides tools for
you to safely determine whether any CAC passes or fails
the manufacturer’s test.
IMPOrTANT!
USING HIGH AIr PreSSUreS AND LArGe TeST
PLUGS MAY PrODUCe DANGerOUS reSULTS!
Please read the warnings supplied with the test kit before
following these instructions.
The test plugs in this set are heavier duty than most.
Notice that each has a thicker washer to prevent cupping
when you tighten the test plugs in the opening. They also
have 4” long cast handles that permit you to tighten them
more easily.
Inspect the inside of the opening and the test plug rubber,
to make sure both of these surfaces are clean and dry.
Test plugs should be installed flush with the opening and
tightened firmly by hand. Install the Test Plug Clamp,
positioning it over the handle so the notched portion of the

4

clamp engages the outside of the inlet/outlet just behind
the bead. Hand tighten the long wing bolts equally, and
check again to make sure that the notched portion of the
clamp is engaged behind the bead at four points. Hand
tighten the wing bolts until snug or use an open-end
wrench to tighten. Do not over tighten!
If the cooler has been removed from the vehicle, position
it so the open stem is pointing up. Next, connect the brass
tester at the quick disconnect side. This tester is equipped
with a pop-off safety valve that has been preset to 35 lbs
maximum pressure. DO NOT CHANGe THIS SeTTING
Or TAMPer WITH THIS DeVICe IN ANY MANNer.
Keep this safety valve clean and dry. Check it occasionally
to make sure that it releases pressure at the 35 lbs setting.
Replacement safety valves and other parts are available if
ever needed.
After checking to make sure everything is properly
secured, introduce air through the air stem using a
common tire chuck. Increase the air pressure to precisely
30 PSI and then measure the pressure drop, if any, for a
period of 15 seconds.
As soon as you have finished testing the charge-air cooler,
return all parts of this set to the plastic case provided, and
close it to keep them clean and dry for their next use.

These complete kits have both
hoses and clamps to replace
ALL hosing from charge-air
cooler inlet and outlet.
Both hoses contained in the
Av-Tekk Hose and Clamp Kits
are hot side compatible.

Now order one part number to get everything you need to
replace ALL hosing for the charge-air cooler.
Av-Tekk Hose & Clamp Kits
Part no.
14000
24045
33375
43500
53875
63000
74500
83037
93040
10250
11334
12278
13358
14318
15316
16278

Inlet size
4”
41⁄2”
33⁄8”
31⁄2”
37⁄8”
3”
41⁄2”
3”
4”
21⁄2”
33⁄4”
27⁄8”
31⁄2”
31⁄8”
311⁄16”
31⁄2”

Outlet size
4”
4”
33⁄8”
31⁄2”
37⁄8”
3”
41⁄2”
33⁄8”
3”
21⁄2”
33⁄4”
27⁄8”
31⁄8”
31⁄8”
311⁄16”
27⁄8”

Av-Tekk Individual Hoses and Clamps
Av-Tekk Hose
Part no.
463-2500-6
463-2875-6
463-3000-6
463-3125-6
463-3375-6
463-3500-6
463-3687-6
463-3750-6
463-3875-6
463-3937-6
463-4000-6
463-4000-8
463-4500-6
463-4500-8

Hose Size
21⁄2” x 6”
27⁄8” x 6”
3” x 6”
31⁄8” x 6”
33⁄8” x 6”
31⁄2” x 6”
311⁄16” x 6”
33⁄4” x 6”
37⁄8” x 6”
315⁄16” x 6”
4” x 6”
4” x 8”
41⁄2” x 6”
41⁄2” x 8”

Av-Tekk Clamp
Part no.
b9226-0256b
b9226-0306b
b9226-0356b
b9226-0406b
b9226-0456b

Clamp Size
21⁄2”
3”
31⁄2”
4”
41⁄2”

to determine corresponding hose and Clamp kit for your cooler, see dimensional drawing section of this catalog.

5

EGR COOLERS

oeM

GriZZlY air