Frequently Asked Questions
Welcome to the CAT Systems Australia Frequently asked questions page.
Here you’ll find clear, factual answers about how our electronic rust protection system works, what it can and can’t do, and how it fits alongside traditional coatings. These answers are designed to help you understand the technology and choose the right protection for your vehicle or equipment.
If you can’t find what you’re looking for, please contact us — we’re happy to help.
1. What is Electronic Rust Protection?
Electronic rust protection helps slow the corrosion process that occurs when metal reacts with moisture and oxygen. The CAT System delivers a very low-level electrical charge to the metal body of your vehicle. This charge helps reduce the rate at which rust forms on painted metal surfaces exposed to harsh environments.
2. How does the CAT System work?
The CAT System uses advanced electronic technology to help protect painted metal panels from corrosion. When correctly installed, the unit emits a consistent electrical potential that spreads across the vehicle’s bodywork, helping to reduce the electro-chemical reaction that causes rust to begin.
3. Does it replace traditional rustproofing?
No. The CAT System is designed to complement physical coatings such as underbody sealants, cavity waxes and paint protection—not replace them. Together, these methods provide the most complete protection available.
4. Is the CAT System suitable for all vehicles?
Yes. The CAT System can be installed on most modern vehicles, including passenger cars, 4WDs, utes, trucks, caravans, and heavy machinery. It operates safely alongside existing vehicle electronics.
5. Does the system protect unpainted or already rusty areas?
Electronic rust protection works best on painted, intact surfaces. It cannot repair existing corrosion or protect areas where bare metal is directly exposed. For vehicles with existing rust, we recommend mechanical treatment and repainting before installation.
6. Will it affect my vehicle’s electrical or computer systems?
No. The CAT System runs on extremely low current and has no negative impact on sensors, computers, batteries, or electrical accessories. It operates independently and safely.
7. Does the system need servicing or maintenance?
Once installed, the CAT System requires no routine maintenance. It runs continuously whenever the battery is connected and draws minimal current, so it won’t drain your battery.
8. Can it be fitted to a new vehicle?
Yes. Installing the CAT System on a new vehicle provides early, long-term protection before corrosion can start—especially valuable for vehicles used near coastal areas or in humid climates.
9. How long does the CAT System last?
Each unit is designed to last for the lifetime of the vehicle. With correct installation and normal use, no further attention is required.
10. Does it stop rust completely?
No system can completely prevent corrosion. The CAT System is designed to help reduce the rate at which rust develops on painted metal surfaces. For best results, combine it with quality coatings, regular washing, and good maintenance practices.
11. Is the CAT System environmentally friendly?
Yes. It contains no hazardous materials and uses no chemicals or sprays. It provides long-term protection without producing waste or emissions.
12. Where can I buy or have the system installed?
You can purchase CAT Systems online and install them yourself — each kit includes full instructions, and free Australia-wide shipping on orders over $100 available (orders under $100 ship at standard Australia Post rates).
Order directly from our CAT Systems Online Store.
13. Which CAT system do I need for my vehicle?
It depends on the size of the vehicle and how you use it. Every system uses the same CAT module; more pads suit bigger vehicles and harsher conditions.
- 2 Pad: cars, SUVs and light 4WDs, mostly on sealed roads.
- 4 Pad: 4WDs, utes and towing, including gravel roads and regional travel.
- 6 Pad: beach driving, boat launching and coastal work vehicles.
- 8 Pad: mine sites, marine work and fleets with constant moisture, salt or chemicals.
Not sure? Contact us with your vehicle and how you use it, and we’ll recommend a system.
14. Can I fit it myself?
Yes. It’s a DIY install with basic hand tools and no drilling, and most people do it in an afternoon. Full instructions come in the kit, and you can read the installation guide before you buy. If you’d rather not, any auto electrician can fit it.
15. Does it work on 12 V and 24 V vehicles?
Yes. The module runs on 12 V or 24 V DC, so it suits cars, 4WDs, trucks and buses. For 48 V DC systems, use our 48 V to 12 V transformer. For fixed equipment on mains power, such as air conditioners, use a 240 V AC to 12 V DC transformer, with its negative earthed to the unit’s metal body.
16. Will it flatten my battery?
No. The module draws a maximum of 25 mA. If the battery drops below 11.8 V (23.6 V on 24 V systems), it cuts back to 9 mA to protect the battery. As with any vehicle, a battery maintainer is a good idea if it will sit unused for months.
17. How do I know it’s working?
A light on the module shows it’s powered and running, and the installation guide explains what each light means. A full signal check needs an oscilloscope, which any auto electrician has.
18. Can I add more pads later?
Yes. A 2 Pad Expansion Pack adds two pads to the same module, and you can add packs at any time.
19. Can I move it to another vehicle?
Yes. The module can be moved to your next vehicle. A re-install kit has the new pads, wiring and fittings you need, and kits are in our online store.
20. What does the 10-year guarantee cover?
Every CAT system comes with a written 10-year product replacement guarantee. Register your system after fitting so we have your details on file. Full terms are on the warranty card in the kit.
21. How much is shipping, and how long does it take?
Shipping is free Australia-wide on orders over $100. Orders under $100 ship at standard Australia Post rates, shown at checkout. Most orders arrive in 2 to 7 days. Unused items in their original condition can be returned within 30 days; see our Refunds and Returns Policy.
22. Does electronic rust protection actually work?
The CAT System is designed to help reduce the rate at which rust forms on painted metal, as one part of corrosion management alongside coatings and regular washing. It has been tested since 1989, including independent salt-fog testing by SGS in 2015. The details are on our Tests and Reports page.
23. Can it be fitted to caravans, trailers and air conditioners?
Yes. Caravans and trailers are fitted much like a vehicle. CAT is also used on air conditioners and fixed plant such as generators and chillers, powered through a 240 V AC to 12 V DC transformer. See electronic rust protection for air conditioners.
24. Do I still need to look after my vehicle?
Yes. CAT is one part of corrosion management. Keep washing off salt and mud, and repair stone chips and paint damage early, because CAT works best on painted, intact surfaces.
Important Notice
The CAT Electronic Rust Protection System is intended to help reduce corrosion on painted metal surfaces when used as directed. It should not be represented as stopping or reversing rust, preventing electrolysis, increasing resale value, or protecting the entire vehicle.
Need More Help?
If you have any other questions, please contact us.