C-7 Injector "Failure"

[MaverickBBD]

I have a C-7 (KAL55907) Manufactured in Greenville in 08.2004. On recent trip it suddenly lost power with noticeable change in sound (tone, pitch, volume). Limped it to exit. Ran and idled very rough. Had it towed to CAT authorized service center(Valley Freightliner, Pacific, WA). No computer trouble codes found. Cylinder cut out revealed #5 & #6 weak. Pulled rail looking for signs of metal for indications of HEUI pump failure. None found. Replacing injectors for #5 and #6. Is this "normal"? Will CAT reimburse me for expense to replace/repair? What caused the failure? I am a maintenance fanatic especially when it comes to filter so I am assuming it was either a mechanical or an electronic failure in the injector(s). I read that a "prototype" injector was used for engines manufactured around this time frame. Anyone know where these injectors came from?

[jimcumminsw]

I would contact your local Caterpillar dealer and work the warranty issue through them. Caterpillar Inc will only work through authorized repair centers such as your local dealer. Here is the link to the dealer list for your reference. http://www.cat.com/about-the-company/global-dealer-network

I would keep all parts and filters for the dealer to review and for Cat if they require them.
Jim W.

[Craig P.]

This seems to be a common issue with the C7. I don't think the condition of the fuel filter has anything to do with the failure. I am keeping my fingers crossed that I don't suffer the same breakdown anytime soon...

Craig

[wagonmaster2]

Everyone raves about how many hundred thousand miles these diesels will run but no one thinks to mention all these little things like injectors, Heui pumps, etc. that will leave you sitting by the side of the road. I have a 2004 Meridian with the C-7 Cat and also keep worrying when one of these items crapping out on me also.

I had 2 gassers before this diesel and never had any roadside problems, and there never seems to be very many posts on the Forums from gassers having to be towed.

Wagonmaster2

[Cat]

Cat has had some problems, some are manufactoring/design issues. But quite a few injector issues are fuel filter issues. People do not use the correct filter or do not prime the fuel filter properly or due not change the fuel filters at the the correct intervals. But all engines have some problems. Cummins had some bad rod problems, workhorse 8.1 had water injestion,and spark plug wire issues, broken crankshafts, Ford spark plug threads problems.
If it goes round and round you can have problems. All we can do is use the right oil,filters and take the best care of them we can---and keep our fingers crossed.

[1ciderdog]

My C-7 has an ocassional "misfire" at about 1600-1700 rpm. Usually when climbing a slight grade or starting from a stop. It doesn't lose power or change sounds but ocasionally jerks just a bit. Adding fuel or shifting down smooths it out. I bought this about a year ago and do not remember it doing this when I bought it. I've changed fuel filter twice and that does not resolve the problem. It does not happen a lot or every time I drive it but doesn't seem like it should do this at all. Anyone have any suggestions or thoughts? (Yes, I know I'll have to take it to a CAT dealer unless someone coomes up witha good suggestion)

[Cat]

Does do it every time the throttle pedal is at certain place? A bad throttle postion sensor can cause a surge that can seem like a missfire. It is located on the pedal. Can you pull diagnostic codes?

[1ciderdog]

Cat - I hadn't thought of the throttle pedal position and will think about that on the next leg of our trip - which will be day after tomorrow. I don't know how to pull the codes - do I need a reader of some type?
Thanks
Bob

[1ciderdog]

Well I went to Carter Cat near Waynesboro, Virginia. BAD NEWS was the Huei pump and injectors were determined to be at fault. The GOOD NEWS is Good Sam Extended Service plan paid for most of what I had done. I have a $500 deductable and also paid some recyling fees, and I had it lubed and an oil change so out the door was a little over $1000. The replaced the injectors as well as the HUEI pump and it certainly runs better, smoother, etc. I did take about 4 1/2 days between getting a dianosis, a Good Sam inspector took about 2 days to get there to evaulate the problem. Good Sam esitmated nine hours, CAT estimated 15 hours and I think they worked on it much more than the 15 hours. The Good Sam policy also pays $100 a day for room & food expenses but that will not really cover all the out of pocket expenses since the motel was $79 a night. Bottom line it runs and we are back on the road. I'll have some conversation with Good Sam about the estimated 9 hour versus what it actually took. Also I should mention the people at Carter Cat were good to deal with and I suspect the work was done correctly.
Bob