if it had roasted itd most likely smell like rotten eggs when it ran

like ed said
something dont sound right
maybe some1 is trying to cover 'parts swapping diagnostic procedures' lol

i wouldnt think the cat could hold that much water unless it was integrated into the muffler

sounds like sabotage to me, if the truck ran at idle for 45 min, -anything- in a cat would burn out, I have seen too many trucks that had a seal go out in the hyd pump of a k21/k25 and filled the crankcase with hyd oil, and had oil blowing out the exhaust until they quit running and they 'self cleaned" the cats in about 20 min after the pump was fixed and oil changed to the proper levels. to get so much water as to effect the operation of the engine would require a hose shoved up the tailpipe when the engine was off and cold.
Now, if the whistle was an intake vac. leak, I can understand the truck trying to richen the mixture, and overloading the cat so it roasted, idling for that much of the time. but no water survived that.
5 minutes should be the maximum allowed time to idle, because -I- said so. (and about 178 other reasons)
but as we say around here, something in that dog just don't hunt...

Sounds very fishy Owen. I think you should question your service provider....

I have had that problem when there was a vacuum leak at the carb and also the whistling noise can come from between the intake and the exhaust manifold. I can't believe they sent it to the shop for that type of problem. Can easily be repaired on site. Rich

exactly
if its a 2007 or later there should be 2 of them (on four cylinder engines)

the second is to check the performance of the cat

the whistling was probably either that belt (did the sound change after he changed it?)
or
the exhaust going past the partially blocked muffler

if the pedal was set improperly the machine would have warned you

now if he told you the cat never reached operating temperature i wonder how it could if it was full of condensation keeping it cool?

check the new 1 see if it has a drain hole in the bottom of it

that would mean that this is a know issue and the original was replaced with a new design to deal with it

where in NY are you im on LI maybe i can help

The truck wasn't loud, just the whistling sound. The truck had been set up this way for two years, isn't there an O-2 sensor or something that would have warned us that the air/fuel mixture was off?

the water is most likely from condensation

my friend the other day said he had the same thing happen in a mitsu

was it loud like you had a hole in the exhaust somewhere?

like edward said the longer stop bolt wouldnt mess with the machine but
but the long idle periods could build condensation instead of blowing it out the pipe

those catalysts are covered under a 3 year warranty (by law)
there may be an hour restriction on that but i think its about 3000 hours

i would tell the operators not to let it idle so much

i dont understand why the manufacturers dont have anything in place to deal with condensation in the muffler

my brand new E350 has a small drain hole in the muffler for condensation to prevent what happened to you

We had called for service because the forklift was making a whistling noise and would barely move. The engine wasn't stalling or bogging down. The tech who came to the site said that it needed a fan belt and that the exhaust was leaking. They took the lift back to their shop and called us to say the muffler had over a gallon of water in it and the cat needed to be replaced. When we got the bill, they also noted that they had rebuilt/replaced the carb but didn't charge us for that. Would the forklift even run with a gallon of water in the muffler?

the longer bolt would only have the same effect as if the operator never slammed the pedal all the way to the floor anyway. -This- did NOT ruin the cat.

I too wonder why they are wanting to replace the cat. what was the problem? very often, in my limited experience, (a little longer than catalytic converters have been common, 30+ years as a forklift professional) I have seen the cat blamed, for a problem not the cats fault, but that the cat was trying to clean up from.

Why do you have to replace the cat? You shouldn't have a problem unless you made it shorter. Is the truck throwing a code? Let me know what is going on with the truck Thanks Rich