Common Exclusions
- Identify common technician actions that result in warranty claim denial.
- Recognize the impact of overloading and improper installation on trailer coverage.
- Distinguish between manufacturer defects and damage caused by negligence or low-voltage conditions.
- Torque wrench — Ensure mounting bolts are tightened to specification without exceeding limits that cause improper installation.
- Multimeter — Test for low-voltage conditions that lead to solenoid damage excluded from typical coverage.
- Pressure gauge — Verify relief valve settings to ensure they have not been subjected to unauthorized tampering.
- GVWR Identification Plate — Verify the Gross Vehicle Weight Rating to determine if overloading has voided the Diamond C warranty.
Improper installation (e.g. over-torqued mounting bolts), improper application, negligence, tampering (e.g. adjusting relief valves), and abuse.
Low-voltage damage to solenoids is typically excluded. Exceeding GVWR voids Diamond C warranty.
How It Works
Installation and Application Standards
Warranty coverage is contingent upon the correct installation and intended use of components. Improper installation, such as over-torquing mounting bolts, or applying a component to a task it was not designed for, constitutes a common exclusion.
Negligence and Tampering
Manufacturers exclude coverage for failures resulting from negligence, abuse, or unauthorized adjustments. Specifically, tampering with settings like relief valves voids the manufacturer's liability for the component's performance.
Electrical and Load Integrity
Electrical components like solenoids are susceptible to low-voltage damage, which is typically excluded from standard coverage. Furthermore, structural and mechanical integrity is tied to weight limits; exceeding the GVWR is a specific trigger for voiding warranties.
Diagnostic Chart
| Symptom | Check | Spec / Expected | Likely cause & fix |
|---|---|---|---|
| Mushroomed or snapped mounting bolts. | Inspect fastener condition and verify torque application during assembly. | Per the applicable manual | Improper installation via over-torqued mounting bolts. Basis: KTI DC Power Unit Troubleshooting Guide (Jan 2019) |
| Solenoid failure with evidence of heat discoloration. | Measure supply voltage at the solenoid under load. | Per the applicable manual | Low-voltage damage, which is typically excluded from coverage. Basis: KTI DC Power Unit Troubleshooting Guide (Jan 2019) |
| Relief valve setting does not match factory presets. | Inspect relief valve seals for evidence of adjustment. | Per the applicable manual | Tampering by adjusting relief valves. Basis: KTI DC Power Unit Troubleshooting Guide (Jan 2019) |
| Structural deformation or hydraulic failure on a Diamond C trailer. | Compare actual load weight against the trailer's GVWR. | Exceeding GVWR voids Diamond C warranty. | Improper application and overloading beyond rated capacity. Basis: KTI DC Power Unit Troubleshooting Guide (Jan 2019) |
At the Bay: Diagnose the Case
CASE 1 / 4
Mushroomed or snapped mounting bolts.
- Test
- Compare
- Correct
Select the next check
Basis: KTI DC Power Unit Troubleshooting Guide (Jan 2019). A likely cause is a hypothesis; confirm it with the applicable service procedure before repair.
Common Bay Mistakes
- ✕ Over-torquing mounting bolts during component replacement.
- ✕ Adjusting relief valves to increase performance beyond factory specs.
- ✕ Ignoring low-voltage issues that lead to solenoid burnout.
- ✕ Failing to verify load weight against the GVWR.
- ✕ Assuming all component failures are covered regardless of installation quality.
Quick Check
Practice only — not scored.
Source: KTI DC Power Unit Troubleshooting Guide (Jan 2019)