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Introduction
| NOTICE |
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Diesel Particulate Filters (DPF) are not applicable to all engines. A Diesel Particulate Filter should typically not be applied to engines that are not regulated. Diesel Particulate Filters are meant for usage on only diesel engines. This technology does not apply to gas engines. Consult with Caterpillar in order to determine if a Diesel Particulate Filter can be used on your engine. |
Thank you for choosing the Caterpillar DPF diagnostic module (DPFdm). The DPFdm is a device designed to continuously monitor the Caterpillar DPF system. The DPFdm provides critical information to the vehicle operator and maintenance staff relative to operation and performance of the Diesel Particulate Filter.
Note: Special Instruction, REHS5606 contains the general guidelines for proper installation of the DPFdm and operational instructions.
Read each section carefully before installing and operating your DPFdm.
The information provided in this manual is general in nature, if you have questions for your specific installation, contact Caterpillar or your Caterpillar dealer.
Note: Federal and CARB verifications require that every vehicle fitted with a Diesel Particulate Filter must install and operate a backpressure monitoring device such as the DPFdm. Contact Caterpillar or your Caterpillar dealer if you have questions regarding your specific requirements.
Warranty and Record of Installation
The statement of warranty for the DPFdm can be found at the end of this User's Manual. Caterpillar dealers will record the installation of the DPFdm as part of the warranty validation for the DPF system.
Be sure to record the information from the DPFdm (serial no.) to validate the product warranty.
DPFdm
The package containing the DPFdm includes the following:
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| Illustration 1 | g01427073 |
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DPFdm Parts List (1) Silicon Weather-Pack Seal (2) Tower half (male), Weather-Pack Connector (3) DPFdm Module - Weather resistant (4) Male Thermocouple Connector (5) Shroud half (female), Weather-Pack Connector (6) Female Weather-Pack Terminal (7) Male Weather-Pack Terminal | |
- Four Silicon Weather-Pack Seals (1)
- One Tower half (male), Weather-Pack Connector (2)
- One DPFdm Module (3) - Weather resistant
- One 271-6538 Male Thermocouple Connector (4)
- One Shroud half (female), Weather-Pack Connector (5)
- Female Weather-Pack Terminal (6)
- Male Weather-Pack Terminal (7)
- One 216-7994 Thermocouple
- Four Self Tapping Mounting Screws w/ washers
- One Users Manual
DPFdm Installation Kit
The installation kit includes the following:
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| Illustration 2 | g01427103 |
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(1) Reducer bored thru
(2) Male run tee (3) Female connector tube | |
- One Reducer Bored Thru (1)
- One Male Run Tee (2)
- One Female Connector Tube (3)
- 20 ft of 1/4 inch Outside Diameter Thick Wall Copper Tube
- 30 ft White 14 AWG Wire
- 30 ft Red 14 AWG Wire
- 20 ft Green 18 AWG Wire
- 20 ft Blue 18 AWG Wire
- Four Terminals (for ECM interface)
- One 3 amp ATO Fuse
- One Fuse Holder for ATO style fuse
- 20 ft Wire Loom
Remote Display Kit
The Remote Display kit includes the following:
- One Remote Display Module
- One Y - Power adapter
System Description
The DPFdm monitors exhaust temperature and backpressure of the DPF system. The DPFdm will warn the operator of the need for filter cleaning or if a potential exhaust system problem exists. The DPFdm is equipped with internal memory and records temperature, backpressure, and alarm events that occur during vehicle operation. Data are accumulated over time and can be downloaded via a serial link to a PC for further analysis. The DPFdm contains alarm outputs which activate lights on a remote display. Contact with your Caterpillar dealer for complete details.
DPFdm Module
The DPFdm is ruggedly packaged and capable of withstanding a wide temperature range. It is designed for retrofit into off-road machines.
Exhaust temperature is monitored with a thermocouple probe installed in the DPF inlet section. Exhaust backpressure is measured with a pressure sensor located within the DPFdm and connected to the DPF inlet using an extension tube. The temperature and pressure data are collected on a continuous basis and monitored to detect conditions that exceed defined limits.
Illustration 3 illustrates the externals of the DPFdm followed by a brief description of each component.
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| Illustration 3 | g01427155 |
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DPFdm Module (1) Mounting Hole (2) System Status Light (3) Over Pressure Alarm (4) Over Temperature Alarm (5) System Problem (6) Alarm Reset Button (7) Pressure Sensor Connector (10) Inlet Thermocouple Connector (11) Alarm Output Connector (12) Mounting Nuts (13) Serial Data Comm Port | |
- Mounting Hole (1). The four grommets mounting holes are used to mount the unit in the vehicle with the self tapping screws and washers supplied with the DPFdm.
- System Status Light (2). A flashing green LED that indicates system status.
- Over Pressure Alarm (3). A red LED comes on when the pre-set limit for a High Backpressure Alarm has been reached.
- Over Temperature Alarm (4). A red LED comes on when the pre-set limit for a High Temperature Alarm has been reached.
- System Problem (5). A red LED comes on whenever the DPFdm detects a problem with the pressure sensor or thermocouple.
- Alarm Reset Button (6). Pressing this button will turn off any of the alarm lights (as long as the alarm conditions no longer exist).
- Pressure Sensor Connector (7). Connection to the pressure sensor.
- Power Pigtail (8). Power is supplied to the DPFdm through this connector.
- Outlet Thermocouple Connector (9). This connector is used only if the DPFdm is being used with two thermocouples. If not in use, leave the red cap on the connector.
- Inlet Thermocouple Connector (10). This connector is always used in all applications.
- Alarm Output Connector (11). Alarm signal is transmitted through this connector to the remote mounted display.
- Mounting Nuts (12). Mounts the enclosure to the base.
- Serial Data Comm Port (13). A communications link is established through this connector to a PC or laptop computer (see below for more information).
DPFdm Backup Battery
The DPFdm contains a backup battery that retains critical parameters in the event of a power loss to the DPFdm. The DPFdm will not operate on this battery if power is lost to the DPFdm. The battery retains stored data, alarm settings, and date/time.
The battery must be replaced every 5 years. Contact your Caterpillar dealer to replace the battery. The procedure requires the use of the DPFdm Communications Software and the ability to apply low pressure to the DPFdm. If you do not have the software or the ability to apply
DPFdm Communications Software
If your shop is equipped with a mobile PC or laptop computer running Windows 95 or newer, you will be able to access the data the DPFdm stores in memory.
The DPFdm software is a user friendly single screen program that operates under the Windows 95, 98, 2000, and XP operating systems. Once installed on a PC, the software allows communication between the PC and the DPFdm. You can develop DPFdm alarm programs, download data, graph the data, and diagnose DPFdm alarms. It is available on CD format and includes DPFdm Communications Manual, software CD, and interface cable that allows communications between the PC and the DPFdm.
Updates are also available via the internet at http://65.202.131.122:8080/. Here you will find the latest updates for the DPFdm Communications Software and the latest firmware. Contact your Caterpillar dealer for a user name and password.
This is a valuable tool that will aid in the diagnosis of DPFdm alarm events. With this software you will be able to determine time/date of an alarm, the back pressure and temperature at the time of the alarm, and what caused the alarm.
For complete details, consult your Caterpillar dealer.
Installation Procedure
The DPFdm installation should be conducted in two parts: mechanical and electrical. Both sections of the installation are included in this manual.
Note: The following DPFdm installation conditions must be met or the warranty may be voided:
- The DPFdm must be mounted in a space where the ambient temperature is below
85 °C (185 °F) under normal vehicle operation. The DPFdm must be located away from direct sources of heat such as the engine, exhaust manifolds, and radiator. - The DPFdm must be mounted in a location where it is not directly exposed to high-pressure steam cleaning, solvents, battery off-gas, or electrical discharge.
- The DPFdm must be connected to a 12 VDC or 24 VDC power supply.
- The DPFdm must not be subjected to voltage supply or power surges greater than 30 VDC.
- The thermocouple and wire supplied with the DPFdm must be used with this unit. Use of any other thermocouple or wire must be approved by your Caterpillar dealer.
Caterpillar recommends that the DPFdm be mounted in a position higher than the DPF inlet. This will reduce clogging of the pressure sensor from water that collects in the tubing between the DPF system and the pressure sensor.
Note: Caterpillar requires that the DPFdm be installed at the same time as the DPF system to validate the DPF system and DPFdm warranties.
Mechanical Installation
Note: Prior to installation of the DPFdm, power must be turned off in the vehicle or the batteries must be disconnected.
Pre-Installation Preparation
- Park the vehicle on a level surface, apply parking brake, and follow all safety precautions as prescribed by shop policy.
- Disconnect the batteries or turn off the master battery disconnect switch.
- Select a location for the DPFdm that meets the above criteria. Use the four mounting holes on the DPFdm as a template to mark four points and drill four 9/32 inch holes. Attach the DPFdm using the self-tapping screws and washers supplied in the DPFdm Kit.
- Every DPF is fitted with a 1/4 inch female NPT boss (Illustration 4), that will accept the fittings identified in the DPFdm installation kit. Before any fittings are installed on the DPF system, the location of the boss must be accessible so that the thermocouple can be easily inserted into the Tee fitting. If the boss is not accessible, the DPF inlet head should be rotated until the boss is accessible.
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| Illustration 4 | g01427200 |
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Connections at DPF inlet (1) Tee fitting (2) Mounting boss in DPF inlet section (3) Copper tubing installed in Tee Fitting (4) Thermocouple installed in Tee Fitting | |
Installation of Fittings, Tubing, and Thermocouple
Note: The following instructions are to be used if you are using a Caterpillar supplied installation kit. Refer to DPFdm "Installation Procedure" (Illustration 14) and "DPFdm and Parts Kit".
- Apply a thin coat of anti-seize to the threads of the Male Run Tee and thread Tee into the boss on the DPF inlet.
- Insert the reducer fitting into the Tee fitting in line with the boss. Tighten the lock nut on the Tee until the Tee is finger tight and then tighten the Tee one turns with a 9/16 inch wrench (Illustration 5).
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Illustration 5 g01427230 Reducer fitting and Tee-Fitting - Insert the thermocouple into the reducer as far as the thermocouple will go, then pull the thermocouple back
50.8 mm (2 inch) . Tighten the lock nut finger tight and then tighten one turn with a 7/16 inch wrench (Illustration 6). If necessary, the thermocouple may be bent once to avoid any interference. Do not bend the thermocouple past 90 degrees.Show/hide table
Illustration 6 g01427245 (1) Two inches - Insert one end of the copper tubing into the fitting on the Tee that is at a 90 degree angle to the boss. Tighten the fitting on the Tee until the fitting is finger tight. Then tighten the fitting one turn with a 9/16 inch wrench (Illustration 7).
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Illustration 7 g01427849 - Loop the tubing at least once when running the tubing from the DPF system to the DPFdm. All
6.1 ± 0.5 m (20 ± 1.5 ft) of the tubing must be used. If the distance between the DPF system and the DPFdm is less than6.1 m (20 ft) , the excess tubing should be looped and mounted in the vehicle. - Thread the female connector to the pressure sensor on the DPFdm with a 3/4 inch wrench. Insert the copper tube into the fitting. Tighten the lock nut on the fitting until the fitting is finger tight. Then tighten the fitting 1-1/4 turns with a 9/16 inch wrench.
Note: All
6.1 ± 0.5 m (20 ± 1.5 ft) of the tubing must be used or the DPFdm warranty may be void.
Electrical Installation
The standard DPFdm is a sealed unit with three external pigtails (refer to Illustration 3 and 15). The male Weather-Pack connector is for 12 VDC or 24 VDC power supply to the DPFdm. The female Weather-Pack connector bundled with the female thermocouple connector marked "INLET" is used for the alarm outputs and the inlet temperature. This thermocouple connector is always used.
The Female Thermocouple connector alone marked "OUTLET" is a secondary temperature input and is only used when using two thermocouples.
Note: When using only one thermocouple, the thermocouple must be plugged into the connector labeled "INLET" or else the DPFdm will alarm.
The standard installation kit contains the minimum required wiring for completing the necessary DPFdm electrical connections. The following instructions are for the standard DPFdm installation kit.
Specialized connectors and wiring harnesses may be available from your Caterpillar dealer.
Note: All wiring should be run in such a way that the wiring is not in contact with heat sources such as the engine, exhaust manifolds and radiators. Protective wire loom supplied with the DPFdm installation kit should be used to cover the wiring. The wire loom can be secured in the vehicle with tie wrap or other fastening devices.
Power Connection
- Locate a 12 V or 24 V power supply that is always available even when the key is turned off.
- Run the red wire from the positive side of the power supply to the DPFdm. Caterpillar recommends that a 3 amp automotive type fuse be installed between the power supply and the DPFdm.
- Run the white wire from either the negative side of the power supply, or any other ground connection, to the DPFdm.
- Insert the power wires in wire loom to protect the wires.
- Refer to "Proper Wiring Connections" for the Weather-Pack crimping procedure.
- After the terminals are crimped on the wires insert:
- The RED wire into port A of the female Weather-Pack connector
- The WHITE wire into port B of the female Weather-Pack connector
- Plug the harness you created into the power pigtail (8) of the DPFdm (Illustration 3).
Proper Wiring Connections
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| Illustration 8 | g01427488 |
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Proper Wiring Connections | |
- Slide Green silicon seals over power, ground, strip
6.35 mm (0.25 inch) of insulation from the wire. Slide the silicon seal to the edge of the stripped insulation. Refer to Illustration 8.Show/hide table
Illustration 9 g01427495 Proper Wiring Connections - Using a Weather-Pack crimping tool, crimp the male terminals on the power and ground wires. Refer to Illustration 9.
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Illustration 10 g01427499 Proper Wiring Connections - Insert the Red wire into spot A of the Female Weather-Pack connector. Insert the white wire into spot B of the Female Weather-Pack Connector. Refer to Illustration 10.
Thermocouple Connection
The thermocouple is supplied with
- Run the thermocouple wire from the DPF inlet to the DPFdm. Cut off any excess wire (Step 1.a and 1.b).
- Strip
12.7 mm (0.5 inch) of brown jacketing and foil from the thermocouple wire exposing the red, yellow, and uninsulated leads. Trim the uninsulated wire back to the edge of the brown jacket.Show/hide table
Illustration 12 g01427516 Male Thermocouple Connector - Strip
6.35 mm (0.25 inch) of insulation from the red and yellow wires. Open the thermocouple connector and remove the red seal. Slide the seal over the wires to the edge of the brown jacket. Insert the yellow wire into the "+" side of the connector. Insert the red wire into the "-" side of the connector. Reassemble the connector.
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Illustration 11 g01427510 Installing the thermocouple connector
(1) Thermocouple wire
(2) Red wire
(3) Yellow wire
(4) Uninsulated wire, trim this wire - Strip
- Peel away the brown shield to reveal the red, yellow, and bare wires.
- Snip the bare wire back at the edge of the brown insulation.
- Attach the yellow wire to the positive "+" pole on the thermocouple connector.
- Attach the red wire to the negative (- or K) pole on the thermocouple connector.
Note: Make sure that the two wires are not touching inside the thermocouple connector. Failure to do so will cause the thermocouple to short out and will cause the DPFdm to alarm.
- Plug the thermocouple connector into the connector on the DPFdm. the thermocouple connector can only be connected in one way.
- The male and female thermocouple connectors can be wired together after they are plugged into each other using mechanics or safety wire. Wire the two halves together using mechanics or safety wire and trim excess wire.
Remote Display Module
A Remote Display Module (RDM) is included with the kit and will warn a driver if the DPFdm detects an alarm event. The Remote Display Module consists of a Power Adapter and a two LED display with
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| Illustration 13 | g01427525 |
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Remote Display Module | |
RDM Connection
- Mount the RDM display somewhere where the vehicle operator can see the RDM display while operating the vehicle in the event of an alarm condition.
- Route the wiring back to the DPFdm.
- The Y-Power adapter included with the RDM contains one leg with a female weather-pack connector and two legs with male weather-pack connectors.
- Plug the female weather-pack connector into the DPFdm.
- Plug the power harness you created into one of the male weather-pack connectors in the Y-Power adapter.
- Plug the RDM into the other male weather-pack connector of the Y-Power adapter.
- Plug the male weather-pack connector on the RDM into the DPFdm.
Note: Once all of the mechanical and electrical connections are complete, reconnect the power to the vehicle. The green status light on the front of the DPFdm should begin flashing indicating that everything is operating correctly. If any alarm lights come on right after the unit is powered up, press the alarm reset button to clear the alarm. If the alarm persists contact your Caterpillar dealer.
Note: The DPFdm power connector MUST BE DISCONNECTED if an electric welder is used on the vehicle. Failure to do may cause severe damage to the DPFdm and may void the DPFdm warranty.
Mechanical Installation Diagram
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| Illustration 14 | g01427569 |
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DPFdm Hardware Installation (1) 1/8 inch diameter Type K Thermocouple (2) Bored Through Reducer (3) Male Run Tee 1/4 inch Tube x 1/4 NPT (4) 1/4 NPT Boss Welded onto DPF inlet module (5) Apply a thin coat of anti-sieze to threads (6) (7) Female Tube Connector | |
Electrical Installation Diagram
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| Illustration 15 | g01427598 |
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DPFdm Electrical Connections (1) DPFdm side (2) Harness side (3) Power Pigtail (4) To battery (5) 12 VDC or 24 VDC unswitched power source (6) Outlet TC (7) Outlet thermocouple (8) Red wire goes to "-" or K (9) Outlet thermocouple only used when two thermocouples are used (10) Yellow wire goes to "+" (11) Bundled inlet TC and alarm output (12) To inlet thermocouple and engine ECU (13) Red wire goes to - or K (14) Inlet thermocouple always used (15) Yellow wire goes to "+" (16) To remote display. Used for red warning lamp (17) To remote display. Used for yellow warning lamp | |
Operation
The DPFdm comes pre-programmed from the factory with a default program. Once power is supplied to the DPFdm and the green status light is flashing, no other operation is required.
Note: The four operational lights on the front of the DPFdm must be monitored for routine maintenance. See Table 1 and 2.
DPFdm Display LED
| Status LEDs and information | |
| System Status | Will blink once every 2 seconds indicating adequate power supply and normal operation. |
| Over-Pressure Alarm | ON if back pressure exceeds set limits / OFF during normal operation |
| Over-Temperature Alarm | ON if exhaust temperature exceeds set limit / OFF during normal operation |
| System Problem | ON if the DPFdm detects a problem with a sensor / OFF during normal operation |
Basic DPFdm Alarm Diagnosis
In the event of an alarm one or both of the lamps in the remote display module will illuminate. In addition, lamps in the DPFdm will also illuminate.
The yellow lamp in the Remote Display Module can indicate one or more of the following alarms:
- Over-Temperature - High exhaust temperature was detected
- Over-Pressure Warning - Back pressure is high
- Temperature Probe Failure - Probe has either shorted or the circuit is open
- Pressure Failure: The pressure tubing is broken or cracked, water has accumulated in the pressure tubing, or the pressure sensor needs attention.
- DPFdm Power failure: If the DPFdm fails and power is still connected, the yellow lamp illuminates in the RDM.
The Red lamp in the Remote Display Module only indicates when the back pressure is exceeding engine manufacturer's specifications. The engine must be shut down whenever it is safe to do so to prevent damage to the engine or DPF system.
In the event a lamp illuminates in the RDM consult Table 2 for very basic DPFdm alarm analysis. It is not intended to be used to determine the cause of a DPFdm alarm. The DPFdm Communications Software must be used in conjunction with the LEDs to diagnose a DPFdm alarm. If you do not have the DPFdm Communications Software you must contact your Caterpillar dealer to assist in diagnosing DPFdm alarms.
| RDM LED Illuminated | DPFdm LED Illuminated | Solution |
| Yellow | The Green LED by System Status is not flashing. | The DPFdm has no power. If there was no noticeable loss of engine power, the machine may be safely driven back to the maintenance yard. |
| Yellow | Green LED is flashing and the Red LED by System Problem is on. | One or more of the sensors providing data to the DPFdm has malfunctioned. Alert maintenance. The machine can be safely driven back to the maintenance facility. |
| Yellow | Green LED is flashing, Red LED by Over-Temp is on and the Red LED by System Problem is on. | The exhaust temperature probe has malfunctioned. Alert maintenance. The machine can be safely driven back to the maintenance facility. |
| Yellow | Green LED is flashing and the Red Over-Temp LED is on (no System Problem LED). | The exhaust temperature is too high. Alert maintenance. The machine can be safely driven back to the maintenance facility. |
| Yellow or Red | Green LED flashing and the Red Over-Pressure LED is on. | The exhaust backpressure has exceeded operational limits. If the Yellow RDM lamp is on and the DPFdm Over-Pressure lamp is on, the filter requires maintenance as soon as possible. If the Red RDM lamp is on and the DPFdm Over-Pressure lamp is on, the filter requires maintenance immediately and the machine must be taken out of service immediately. |
Note: Any alarm events must be investigated immediately. Failure to do so may result in severe damage to the DPF or the engine. Failure to diagnose any alarm events may void the warranty on the DPF or DPFdm.
Contact Information
For further information on installation, operation or troubleshooting contact your local Caterpillar dealer at http://www.cat.com.
DPFdm Electro-Mechanical
| Housing | Metallic enclosure, near weatherproof seal, with sealing gland type fittings for wire egress. |
| Dimensions | 10 x 6 x 3.5 with a tab/flange at each end for surface mounting. |
| Wiring Connections | Via Weather-Pack and Mini Type-K connectors on 3 separate pigtails. No user serviceable connectors are inside the enclosure. |
| Wiring Egress | Sealing gland type fittings. Sealed serial connection on electronics module cover. |
| Pressure Connection | Via - 18 Male NPT directly onto integral pressure transducer. |
| Ambient Operating Temperature | -30 to 85 °C (-22 to 185 °F) |
DPFdm Electrical
| Supply Voltage | Input range 12 to 24 VDC |
| Supply Current | 50mA average current, 150mA max current including all sensor excitation. |
| Cold Junction Compensation (CJC) | Integral via on board sensor at thermocouple connection point. CJC accuracy to add less than +/-1.5 °C error over specified DPFdm ambient operating range (typical will be less than +/-0.6 °C) |
| ADC Resolution | 10 bit unipolar; will result in approximately 2 °C (36 °F) resolution for temperature and 0.1 inch Hg for pressure. |
| ADC Accuracy | Max (over temp): +/-4 bits%. |
| System Accuracy | Temperature Error Max: +/-5 °C (typical +/-2 °C). Pressure Error: +/- 1.5% typical, 3% max. |
| Sample Capacity | The DPFdm is capable of storing approximately 260,000 records in internal memory. Dynamic allocation of memory space will be implemented to allow for asynchronous event storage (e.g. alarms). |
| RTC | Integral real-time clock with 10 year life expectancy lithium cell backup. Ambient temperature ( |
| Glitch Recovery | The DPFdm microprocessor will be equipped with a hardware watch dog timer to restore normal operation in the event of a system upset. |
| Alarm Outputs | Two outputs. Alarm 1 is an open collector transistor output. Alarm 2 is a relay output. The normally closed contacts of this relay are used to add a level of fail-safe integrity to the system in the event of a system power failure. The relay will short Terminal strip TS2, Position 4 to ground upon alarm condition or in the event of a power failure of the DPFdm. |
| Serial Data Port | Multi-wire serial interface for connection to a PC. A fixed baud rate of 115K/baud is supported. |
| Software Restart | Upon interruption and re-application of power, the DPFdm will commence normal operation including data logging and alarm functions. |
Pressure Transducer
| Housing | Cylindrical machined 316 SS housing. Unit will be contained within the DPFdm. |
| Diaphragm | 316L |
| Operating Temp Range | -40° to 125 °C (-40 to 257 °F) |
| Shock | 100 G for 11mSec. |
| Vibration | 10G at 20-2000 Hz. |
| Lifetime | 1 million cycles. |
| Temp Compensated Range | -10° to 85°C (14° to 185 °F) |
| FS Range | 0 - 20 inch Hg (0-10 PSIG) suggested. |
| Accuracy | Type: +/- 1.5%FS over temp; Max; +/-3%FS. |
| Pressure Connection | Via - 18 Male NPT directly onto integral pressure transducer. |
| Supply Power | Power will be supplied through the DPFdm module. The power supply will be pre-regulated and surge protected. |
Temperature Sensor
| Type | K thermocouple. |
| Package | 1/8 inch dia x 8 inch long Inconel 600 insertion probe compatible with Swagelok type compression fitting. Ungrounded thermocouple in hi-temp magnesium oxide insulator with MGO cement cap. Provided with |
| Temp Range (withstand) | -100° to 1000°C (-148° to 1832 °F) continuous. |
| Temp Range (operational) | 0° to 1000°C (32° to 1832 °F) |
| Sensor Accuracy | Special Limits TC wire used: +/-1.1 °C or +/-0.4%rdg whichever is greater over range 0° to 1000°C (32° to 1832 °F). |
Your Warranty Rights And Obligations
VERIFIED PRODUCT WARRANTY
Caterpillar Inc. warrants the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system, vehicle or equipment, as specified in the owners manuals. Where a warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect, or improper maintenance of your vehicle or equipment. Review your owners manual for other warranty information. Your diesel emission control system may include a core part (e.g., particulate filter, diesel oxidation catalyst, selective catalytic reduction converter) as well as hoses, connectors, a backpressure monitor (if applicable), and other emission-related assemblies. Where a warrantable condition exists, Caterpillar will repair or replace your diesel emission control system at no cost to you including diagnosis, parts, and labor.
WARRANTY COVERAGE
For engines used in verified applications, the warranty period will be in years or hours or miles of operation, whichever occurs first, based on the following chart:
| Engine Type | Engine Size | Minimum Warranty Period |
| On-Road | Light heavy-duty, 70 to 170 hp, Gross Vehicle Weight Rating (GVWR) less than 19,500 lbs. | 5 years or 60,000 miles |
| Medium heavy-duty, 170 to 250 hp, GVWR from 19,500 lbs. to 33,000 lbs. | 5 years or 100,000 miles | |
| Heavy heavy-duty, exceeds 250 hp, GVWR exceeds 33,000 lbs. | 5 years or 150,000 miles | |
| Heavy heavy-duty, exceeds 250 hp, GVWR exceeds 33,000 lbs., and trucks are:
1. Typically driven over 100,000 miles per year, and 2. Have less than 300,000 miles on the odometer at the time of installation. |
2 years, unlimited miles | |
| Off-Road (includes portable engines) and Stationary | Under 25 hp, and for constant speed engines rated under 50 hp with rated speeds greater than or equal to 3,000 rpm | 3 years or 1,600 hours |
| At or above 25 hp and under 50 hp | 4 years or 2,600 hours | |
| At or above 50 hp | 5 years or 4,200 hours |
If any emission-related part of your diesel emission control system is defective in design, materials, workmanship, or operation of the diesel emission control system thus causing the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, within the warranty period, as defined above, Caterpillar will repair or replace the diesel emission control system, including parts and labor; provided that the following items are excluded from this warranty: (1) gaskets, (2) clamps, and (3) the batteries for the diagnostic module.
In addition, Caterpillar will replace or repair the engine components to the condition they were in prior to the failure, including parts and labor, for damage to the engine proximately caused by the verified diesel emission control strategy. This also includes those relevant diagnostic expenses in the case in which a warranty claim is valid. Caterpillar Inc. may, at its option, instead pay the fair market value of the engine prior to the time the failure occurs.
INSTALLATION OF VERIFIED PRODUCTS WARRANTY
Your Caterpillar dealer warrants that the installation of a diesel emission control system is free from defects in workmanship or materials which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the Requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706. The warranty period and the extent of the warranty coverage provided by your Caterpillar dealer is the same as the warranty provided by Caterpillar Inc. on the diesel emission control system, and the same exclusions apply.
OWNERS WARRANTY RESPONSIBILITY
As the (vehicle, engine, equipment) owner, you are responsible for performing the required maintenance described in your owners manual. Caterpillar recommends that you retain all maintenance records and receipts for maintenance expenses for your vehicle, engine, or equipment, and diesel emission control system. If you do not keep your receipts or fail to perform all scheduled maintenance, Caterpillar may have grounds to deny warranty coverage. You are responsible for presenting your vehicle, equipment, or engine, and diesel emission control system to a Caterpillar dealer as soon as a problem is detected. The warranty repair or replacement should be completed in a reasonable amount of time, not to exceed 30 days. If a replacement is needed, this may be extended to 90 days should a replacement not be available, but must be performed as soon as a replacement becomes available.
If you have questions regarding your warranty rights and responsibilities, you should contact Caterpillar Inc. at 1-877-CAT-0909 or the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731, or (800) 363-7664, or electronic mail: helpline@arb.ca.gov.
CATERPILLAR EXCLUSIONS AND LIMITATIONS (WHICH DO NOT LIMIT OR MODIFY THE PROVISIONS OF THE ABOVE WARRANTY IN ANY WAY)
THIS IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY CATERPILLAR. CATERPILLAR MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. FURTHER, THE WARRANTY SET FORTH ABOVE MAY NOT APPLY TO THE RESULTS OF ACCIDENT, ABUSE, NEGLECT, VANDALISM, ACT OF GOD, USE CONTRARY TO CATERPILLAR'S INSTRUCTIONS, IMPROPER INSTALLATION, REPAIR, REPLACEMENT OR MODIFICATION BY ANYONE OTHER THAN CATERPILLAR (EXCEPT WITH CATERPILLAR'S WRITTEN APPROVAL). CATERPILLAR does not warrant against infringement under the uniform commercial code by reason of the use of such verified products by Buyer in combination with other materials or in the operations of any process. Except to the extent otherwise provided in the Warranty above, CATERPILLAR SHALL NOT BE LIABLE FOR LOSS OF PROFITS, DIRECT, INDIRECT, INCIDENTAL, SPECIAL, CONSEQUENTIAL OR OTHER DAMAGES ARISING OUT OF OR RESULTING IN ANY WAY FORM ANY DIESEL EMISSION CONTROL SYSTEM OR FORM ANY CAUSE WHATSOEVER, REGARDLESS WHETHER BUYER'S CLAIM IS BASED ON, WITHOUT LIMITATION, CONTRACT, TORT, NEGLIGENCE, PRODUCTS, LIABILITY, OR ANY OTHER CAUSE. Except to the extent provided otherwise in the Warranty above, CATERPILLAR's total, complete and exclusive liability hereunder shall be limited to repair of replacement of the verified device, repair or replacement of the engine or payment for the market value of the engine prior to the failure as provided above. Further, CATERPILLAR is not responsible for repair or replacement of gaskets, clamps or diagnostic module batteries.