Performance and Fuel Economy

Troubleshooting
 Performance Complaint
Work Sheet
Chassis Number:
Inspection
Engine Serial Number:

1 Perform a DAVIE log file download; print and attached the document to the performance complaint worksheet
If active errors were found please follow the diagnostic troubleshooting guide from Rapido
Done
Visual Inspection
2 Perform visual air intake piping inspection for loose connection, perforated pipes, routing for rubbing area.
Passed Failed Comment:

3 Perform air filter inspection

Passed Failed Comment:

5 Perform charge air cooler visual inspection. Check for excessive debris or dust in charge air cooler core.
Passed Failed Comment:

6 Perform visual inspection of turbine and compressor vanes for damaged vanes on turbo
Passed Failed Comment:

7 Check for excessive turbo end play and radial movement. Manual inspection.
Passed Failed Comment:

8 Check for visual fuel line leaks, check/record fuel filter brands, filter bases and any modifications to the system.
Passed Failed Comment:

9 Check for visual coolant leaks, level and any modifications to the system.
Passed Failed Comment:

10 Check for visual oil leaks, level and any modifications to the system.
Passed Failed Comment:

11 Check for debris/algae in fuel tank(s). Take fuel sample.

Passed Failed Comment:

12 Check for cooling fan operation

Passed Failed Comment:
 Performance Complaint
Work Sheet
Chassis Number:
Inspection
Engine Serial Number:

13 Inspect for loose/unconnected, or damaged wiring harnesses and connections

Passed Failed Comment:

14 Inspect outlet tube of Open Crankcase Filter system for oil or debris:
Passed Failed Comment:

15 Inspect engine drive belts for tension and condition

Passed Failed Comment:

16 Inspect exhaust manifold, castings, and connections for leaks

Passed Failed Comment:

17 Inspect tire wear/condition, 5th wheel condition/position.

Passed Failed Comment:

Comment:
 Performance Complaint
Work Sheet
Chassis Number:
Measurement
Engine Serial Number:
Road Test Loaded: Unloaded: GCVW: Ambient Air Temp.
1 Perform road test and try to re-create the complaint.
Re-created Not re-created Comment:

2 Road Test and record MAX boost pressure data using DAVIE.
Actual Measurement:

3 Measure air inlet restriction at intake piping with vacuum gauge:

Maximum allowable 20 in H2O Actual Measurement:
Comments:

4 Road Test and record unit pump fuel pressure data using DAVIE.
Please refer to Rapido for specs Actual Measurement:
Comments:

Systems
Air Intake System

1 Air to Air core leakage

Allowable Leakage: 5psi drop in 15 sec. @ 30 psi Actual Measurement:
Comments:

2 Visually inspect air to air cooler core for damaged fins and dirt accumulation blocking flow. Clean core if needed
Comments:
 Performance Complaint
Work Sheet
Chassis Number:
Measurement
Engine Serial Number:
Overhead Systems (Must be performed cold)
1 Measure Intake and Exhaust Valve Clearance per Rapido Procedure
Passed Failed Actual Measurement: Refer to Overhead Adjustment tab
Comments:

2 Visually inspect overhead system while performing valve clearance

Passed Failed Actual Measurement:
Fuel System
1 Measure fuel pressure inlet restriction after primary fuel filter (Frame Mounted):
Actual Measurement:
Replace primary and secondary fuel filter and verify if complaint still present

2 Install sight glass on the supply line after primary fuel filter and check for aeration
Comments:
Crankcase and Oil Systems
1 Record Engine Oil Pressure at the following RPM using DAVIE
Idle: 1000 rpm 1900 rpm
Electronic Control System PMCI
Perform the following tests with DAVIE as specified in Rapido & attach results to this document or Support Net Case
1 Cylinder Compression Test
4 Automated Cylinder Performance Test
5 EGR & VTG Condition Test
Overhead Adjustment (Measurement Check Performed Cold)
Cylinder #1 Cylinder #2 Cylinder #3 Cylinder #4 Cylinder #5 Cylinder #6
Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust

Before

After

Date

Chassis #

Miles / Kilometers

Customer Name