CAT C-7 just quits

Catpowered · 08-21-2011, 01:27 PM

Cruising along on the interstate I thought I detected a slight miss in the CAT C-7 engine in my 04 Meridian. Upon exiting the interstate and pulling up to the stop sign, the engine died. I tried to restart it, but it would crank but not fire. I tried this several times with no luck. So here I am, blocking the exit ramp with cars and trucks stacking up behind me. I put out the reflective triangles and called for roadside service...but I knew it would be hours or days before they reached me in this remote area. I tried to start it once more, this time with the accelerator pedal depressed...it worked! The engine fired and then came up to rpm...I revved it to the limit a few times and then pulled up the triangles and drove off...whew! The engine seemed to still have a slight miss so I had a local truck shop change both the fuel filters. However, it still seems to have that slight miss but no problem with idle now. I added a can of Diesel Clean at my last stop so haven't driven it since....I am somewhat apprehensive about my return to Arizona from Wisconsin. I contacted the Freightliner dealer that services the coach and he thought it may be an air leak in the fuel system. I traced the fuel lines from the tank to the engine and could find nothing wrong. Anyone experience this slight miss in their CAT engine and what was the cause?

MaverickBBD · 08-21-2011, 01:38 PM

You should see if there are any computer codes. You maybe starting to loose an injector. Rumor has it that CAT had an injector manufacturer during that time period that was less then satisfactory. If it were the HEUI pump on the electronic side it will throw a code. HEUI pumps have been know to go bad also. Again see if there are any codes and maybe have a cyclinder cut out done. That would at least be an indication of which cyclinder(s) it is.

Catpowered · 09-20-2011, 03:29 PM

Here is the rest of the story: The problem was the HEUI (Hydraulic-Electric Unit Injector), the high pressure fuel pump. It failed after only two years out of warranty and only 48,000 miles. It chewed itself up, leaving metal particles to clog up the injectors. The local Freightliner service changed the pump and now it runs fine but problems could develop later on if a particle gets lodged in an injector. Caterpillar recommended changing all six injectors (about five grand cost with labor)and I would have done that if cost was no object. If a problem does develop I will be forced to change them. After all this I am no fan of Cat engines!

MaverickBBD · 09-20-2011, 03:38 PM

Upon researching my failed injectors I discovered that CAT had a problem with injector manufacturers in the 2003 to 2005 era. I hit a dead end in attempting to determine who they were and what the problem was. It is sort of like getting someone in the "official" CAT world to admit that ULSD might have been a contributing factor.
Did you have a cylinder cut out performed to determine which injector was bad? If so, you should get a copy of the results so that you can monitor injector performance.
You might want to consider running B-10 or B-15 diesel for a while to increase the lubricity of the fuel. Just a thought.

Catpowered · 09-20-2011, 07:17 PM

Quote:

Originally Posted by MaverickBBD

Upon researching my failed injectors I discovered that CAT had a problem with injector manufacturers in the 2003 to 2005 era. I hit a dead end in attempting to determine who they were and what the problem was. It is sort of like getting someone in the "official" CAT world to admit that ULSD might have been a contributing factor.
Did you have a cylinder cut out performed to determine which injector was bad? If so, you should get a copy of the results so that you can monitor injector performance.
You might want to consider running B-10 or B-15 diesel for a while to increase the lubricity of the fuel. Just a thought.

My injectors did not fail. The HEUI failed.

MaverickBBD · 09-21-2011, 09:00 AM

Quote:

Originally Posted by Catpowered

My injectors did not fail. The HEUI failed.

I realize that. The point being your injectors will be even more subject to failure with an metal particles left over.

CAT Lover · 09-21-2011, 04:56 PM

2375 the over rev warning light comes on, @ 2400 the fuel cutoff kicks in.

Catpowered · 09-22-2011, 05:12 PM

Quote:

Originally Posted by MaverickBBD

I realize that. The point being your injectors will be even more subject to failure with an metal particles left over.

C

How do I change my user name from Catpowered to Crappowered?

Catpowered · 10-05-2011, 01:22 PM

Quote:

Originally Posted by Catpowered

Here is the rest of the story: The problem was the HEUI (Hydraulic-Electric Unit Injector), the high pressure fuel pump. It failed after only two years out of warranty and only 48,000 miles. It chewed itself up, leaving metal particles to clog up the injectors. The local Freightliner service changed the pump and now it runs fine but problems could develop later on if a particle gets lodged in an injector. Caterpillar recommended changing all six injectors (about five grand cost with labor)and I would have done that if cost was no object. If a problem does develop I will be forced to change them. After all this I am no fan of Cat engines!

More to this story. I asked Caterpillar Corp. for a one-time good will payment to cover the cost of this HEUI because of it's early failure and they replied with a flat "NO".

wagonmaster2 · 10-05-2011, 09:45 PM

Besides your HEUI problem Cat also seems to have problems with the sealed fan hub bearing failing prematurely during those same years of manufacture. In 2004 Cat went from a greaseable bearing to the sealed one and I've read of them failing any where from 16,000 miles on up. And when it does fail the fan will tear up the shroud and possibly get into the CAC and/or radiator. Of course, Cat claims no responsibility for this situation. I've checked to see about maybe having mine changed, 54,000 miles, as part of my maintenance but have gotten estimates of anywhere between $1,000 - $2,000 which will be a little hard to take.

Wagonmaster2
2004 Meridian 36G Cat C-7 330 HP

Catpowered · 10-06-2011, 03:05 PM

I have my fan hub checked for "play" at every oil change. So far it has been good.

SVTotem · 10-06-2011, 03:43 PM

Can the hub be checked for play from below? Must the belts be loosened to perform the check?

Catpowered · 10-08-2011, 03:42 PM

Quote:

Originally Posted by SVTotem

Can the hub be checked for play from below? Must the belts be loosened to perform the check?

I don't think so, one wouldn't be able to reach it. I think you would have to access it from the top, under the bed in our coach. Regarding the belt, I don't know about that but I suspect if there was alot of play it would show up even with the belt attached.