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S3000 Common Rail

Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 002 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 46472233
Test Oil Temperature- 40 C

EM
Engine:- 182 B 4000 1.9 JTD
Solenoid Resistance @ 20C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 50-55 <35.0/55.0 Max Fuel


400 250 700 9.0-10.0 <20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I


IE

Start of Injection (S.O.I)


D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.


ER
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 012 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 05 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-961/980
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 73-77 <35.0/55.0 Max Fuel
S

400 250 700 14.0-15.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
N

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
ER

When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 015 Testing Prerequisites
0 986 435 005 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 668 070 02 87
Test Oil Temperature- 40 C

EM
Engine:- OM668-941
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 52-57 <35.0/55.0 Max Fuel
S

400 250 700 11.0-12.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
N

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
ER

When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 019 Testing Prerequisites

Type Designation:- CR/IPS19/ZERAK10S Mount Suitable Test Pump

S
Manufacturer I.D.:- FIAT 46547897 Test Oil Specification- ISO 4113

EM
Engine:- 188 A 2.000 1.9JTD Test Oil Temperature- 40 C

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
SY
Close protective cover.

Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Commen
RPM BAR cc/1000 Mm3st/ccmin ts
EL

1000 1000 1200 N/A - Purge


System
2000 1500 1200 N/A - Check for
S

Leaks
1500 1350 900 60-65 <35.0/55.0 Max Fuel
IE

400 250 700 12.0-13.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 021 Testing Prerequisites
0 986 435 007 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 7700 107 165
Test Oil Temperature- 40 C

EM
Engine:- F9Q 1.9DCi
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 64-69 <35.0/55.0 Max Fuel
S

400 250 700 9.0-10.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
N

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
ER

When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 025 Testing Prerequisites
0 986 435 020 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 06 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-961 611-981
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 65-70 <35.0/55.0 Max Fuel
S

400 250 700 13.0-14.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
N

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
ER

When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 029 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS17/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 13 53 7 785 437
Test Oil Temperature- 40 C

EM
Engine:- 30 6 D1 3.0D
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 61-66 <35.0/55.0 Max Fuel
S

400 250 700 5.0-7.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
N

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
ER

When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 030 Testing Prerequisites
0 986 435 011 Mount Suitable Test Pump
Type Designation:- CR/IFS17/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 13 53 2 354 045
Test Oil Temperature- 40 C

EM
Engine:- 30 4 D1 2.0D
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 55-60 <35.0/55.0 Max Fuel
S

400 250 700 8.0-9.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
N

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
ER

When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 035 Testing Prerequisites
0 986 435 012 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 613 070 01 87
Test Oil Temperature- 40 C

EM
Engine:- OM611.981 OM611.987
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 71-76 <35.0/55.0 Max Fuel
S

400 250 700 12.0-13.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
N

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI

from nozzle holes. Rail pressure should be 150-200BAR.


ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 036 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS17/ZEREW10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 96533448
Test Oil Temperature- 40 C

EM
Engine:- PSA2.2HDi 4HX
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 62-66 <35.0/55.0 Max Fuel


IE

400 250 700 11.0-12.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 038 (0 986 435 016) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFS17/ZEREK10S TEST OIL: ISO 4113

LT
O.E.M. REF: RENAULT 8200 010 074 TEST OIL TEMP: 40C
ENGINE: G9T-710 SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 76-78 <35.0 <55.0 Max Fuel

400 250 700 8-9 <20.0 <9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I

400 400 60 0.2-3.0 - - Pre Injection


N
LI

Start of Injection
ER

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
M

5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 044 Testing Prerequisites
0 986 435 003 Mount Suitable Test Pump
Type Designation:- CR/IPS17/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 96375360/1980-72
Test Oil Temperature- 40 C

EM
Engine:- 2.0 HDi
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 57-60 <35.0/55.0 Max Fuel


400 250 700 10.0-11.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 047 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS17/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 13 53 778 984
Test Oil Temperature- 40 C

EM
Engine:- 30 6 D1
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 70-72 <35.0/55.0 Max Fuel


400 250 700 8.0-9.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 048 Testing Prerequisites

Type Designation:- CR/IFS17/ERAK10S Mount Suitable Test Pump

S
Manufacturer I.D.:- BMW 13 53 7 785 574 Test Oil Specification- ISO 4113

EM
Engine:- 25 6D1 Test Oil Temperature- 40 C

Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
EL

1000 1000 1200 N/A - Purge


System
2000 1500 1200 N/A - Check for
S

Leaks
1500 1350 900 55-60 <35.0/55.0 Max Fuel
IE

400 250 700 7.0-9.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 049 Testing Prerequisites

Type Designation:- CR/IFS17/ZERAK10S Mount Suitable Test Pump

S
Manufacturer I.D.:- BMW 1353 7 785 983 Test Oil Specification- ISO 4113

EM
Engine:- Test Oil Temperature- 40 C

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
SY
Close protective cover.

Pump Speed Rail Pressure Pulse Width Delivery Comments


RPM BAR cc/1000
EL

1000 1000 1200 Purge System


2000 1500 1200 N/A Check for Leaks
S

1500 1350 900 53.0-57.0 Max Fuel


400 250 700 6.0-8.0 Idle
IE

1500 1350 900 <35 Max Back leakage


2000 1350 Run pump only <12.5 Max Back leakage
D

400 150-200 700 - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 054 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZERAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 11 87
Test Oil Temperature- 40 C

EM
Engine:- OM646-951/961

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 73-77 <35.0/55.0 Max Fuel


400 250 700 14.0-15.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 055 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZERAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 11 87
Test Oil Temperature- 40 C

EM
Engine:- OM646-951/961

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 73-77 <35.0/55.0 Max Fuel


400 250 700 14.0-15.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 057 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS17/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1980-78
Test Oil Temperature- 40 C

EM
Engine:- RHW 2.0HDi 16v
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
EL

1000 1000 1200 N/A - Purge


System

2000 1500 1200 N/A - Check for


S

Leaks
1500 1350 900 55-60 <35.0/55.0 Max Fuel
IE

400 250 700 11.0-12.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 059 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- VM 1506 2036F
Test Oil Temperature- 40 C

EM
Engine:- 2.5CRD

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
EL

1000 1000 1200 N/A - Purge


System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 80-83 <35.0/55.0 Max Fuel


IE

400 250 700 11.5-12.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T016-3052 Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 062 Testing Prerequisites
0 986 435 077 Mount Suitable Test Pump
Type Designation:- CR/IPS17/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 96400887
Test Oil Temperature- 40 C

EM
Engine:- PSA 2.0HDi RHY
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 60-64 <35.0/55.0 Max Fuel


400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 063 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS17/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200010075
Test Oil Temperature- 40 C

EM
Engine:- 1.9 DCi Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Comments
RPM BAR cc/1000
EL

1000 1000 1200 Purge System


2000 1500 1200 N/A Check for Leaks
1500 1350 900 55-60 Max Fuel
S

400 250 700 10.0-12.0 Idle


IE

1500 1350 900 <35 Max Back leakage


2000 1350 Run pump only <12.5 Max Back leakage
D

400 150-200 700 0.01-0.1 S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052 Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 064 Testing Prerequisites
0 445 110 101 Mount Suitable Test Pump
Type Designation:- CR/IPL17/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- HYUNDAI 33800-27000
Test Oil Temperature- 40 C

EM
Engine:- D3EA/D4EA
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 65-68 <35.0/55.0 Max Fuel


400 250 700 10.0-12.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 068 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 46787376
Test Oil Temperature- 40 C

EM
Engine:- 182 B 9.000/ 186 A 6.000 1.9JTD
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
EL

1000 1000 1200 N/A - Purge


System

2000 1500 1200 N/A - Check for


S

Leaks
1500 1350 900 77-80 <35.0/55.0 Max Fuel
IE

400 250 700 10.0-11.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 069 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 08 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-981/OM611-987
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
EL

1000 1000 1200 N/A - Purge


System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 72-75 <35.0/55.0 Max Fuel


IE

400 250 700 14.0-15.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 069 Testing Prerequisites
0 445 110 070 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- 611 070 08 07
Test Oil Temperature- 40 C

EM
Engine:- OM611.981 / 987
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 72-75 <35.0/55.0 Max Fuel


400 250 700 14.0-15.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 072 Testing Prerequisites
0 986 435 071 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 09 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-962
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 64-68 <35.0/55.0 Max Fuel


400 250 700 12.0-13.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 075 Testing Prerequisites
0 986 435 076 Mount Suitable Test Pump
Type Designation:- CR/IPL20/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 96386523
Test Oil Temperature- 40 C

EM
Engine:- 8HX / 8HZ
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 43-47 <35.0/55.0 Max Fuel


400 250 700 10.0-11.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 076 Testing Prerequisites
0 986 435 077 Mount Suitable Test Pump
Type Designation:- CR/IPS17/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 96533448
Test Oil Temperature- 40 C

EM
Engine:- PSA2.0HDi RHS/RHY
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 60-64 <35.0/55.0 Max Fuel


400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 078 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS19/ZERAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- VOLVO 8658350
Test Oil Temperature- 40 C

EM
Engine:- D5244T
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 69-71 <35.0/55.0 Max Fuel


IE

400 250 700 9.0-10.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052 Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 080 Testing Prerequisites
0 986 435 084 Mount Suitable Test Pump
Type Designation:- CR/IFL17/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 13 53 7 787 234
Test Oil Temperature- 40 C

EM
Engine:- 20 4 D4 / 30 6 D2
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 80-84 <35.0/55.0 Max Fuel


400 250 700 14.5-15.5 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 081 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:-
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 84.0-87.0 <35.0/55.0 Max Fuel


IE

400 250 700 8.0-10.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 083 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZERAK10S TEST OIL: ISO 4113
O.E.M. REF: FIAT 55184536 TEST OIL TEMP: 40C
ENGINE: 1.3JTD, OPEL 1.3CDTI SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 65-70 <35.0 <55.0 Max Fuel

400 250 700 7-9 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

400 400 60 0.1-3.0 - - Pre Injection

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 084 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFL19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200084534
Test Oil Temperature- 40 C

EM
Engine:- REN 2.2 DCi 110KW G9T-742
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 68-73 <35.0/55.0 Max Fuel


IE

400 250 700 11.5-12.5 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 087 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200101135
Test Oil Temperature- 40 C

EM
Engine:- REN 1.9 DCi OPEL 1.9 DTi
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 77-80 <35.0/55.0 Max Fuel


IE

400 250 700 11.0-12.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052 Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 090 Testing Prerequisites
0 986 435 033 Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 668 070 08 87
Test Oil Temperature- 40 C

EM
Engine:- OM668-914
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 56-60 <35.0/55.0 Max Fuel


400 250 700 14.0-15.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 091 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- HYUNDAI 33800-4A000
Test Oil Temperature- 40 C

EM
Engine:- D4CB 2.5CRDI
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 78-84 <35.0/55.0 Max Fuel


IE

400 250 700 5.5-7.5 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 093 Testing Prerequisites
0 986 435 035 Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 03 87
Test Oil Temperature- 40 C

EM
Engine:- OM628-962
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 67-71 <35.0/55.0 Max Fuel


400 250 700 11.0-12.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 095 Testing Prerequisites
0 986 435 037 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 613 070 05 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-981 / OM611-987
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 75-78 <35.0/55.0 Max Fuel


400 250 700 9.0-10.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 096 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- OM612.965
Test Oil Temperature- 40 C

EM
Engine:- MB
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 70-75 <35.0/55.0 Max Fuel


IE

400 250 700 10.0-12.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 098 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- OM612.965
Test Oil Temperature- 40 C

EM
Engine:- MB
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 70-75 <35.0/55.0 Max Fuel


IE

400 250 700 10.0-12.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 100 Testing Prerequisites
0 986 435 041 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 13 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-962
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 67-72 <35.0/55.0 Max Fuel


400 250 700 11.0-12.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 101 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- HYUNDAI 33800-27000
Test Oil Temperature- 40 C

EM
Engine:- D3EA/D4EA
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 67-72 <35.0/55.0 Max Fuel


400 250 700 10.5-11.5 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 102 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS19/ERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200 112 289
Test Oil Temperature- 40 C

EM
Engine:- G9T-722 / G9T-750 2.2DCi
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 57-62 <35.0/55.0 Max Fuel


IE

400 250 700 10.0-11.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 106 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 14 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-981 OM644-987
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 73-77 <35.0/55.0 Max Fuel


400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 108 Testing Prerequisites
0 986 435 047 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 16 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-981 OM644-987
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 73-77 <35.0/55.0 Max Fuel


400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 110 Testing Prerequisites
0 986 435 080 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200 100 272
Test Oil Temperature- 40 C

EM
Engine:- 1.9 DCi
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 64-67 <35.0/55.0 Max Fuel


400 250 700 10.0-11.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 111 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- Fiat 55192534
Test Oil Temperature- 40 C

EM
Engine:- 192 B / 537 A
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 85-90 <35.0/55.0 Max Fuel


400 250 700 9.0-10.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 112 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 55184535
Test Oil Temperature- 40 C

EM
Engine:- 1.9JTD 8V
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 85-90 <35.0/55.0 Max Fuel


IE

400 250 700 8.5-9.5 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 113 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- VW 057130276H
Test Oil Temperature- 40 C

EM
Engine:- AKF3.3TDi
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
EL

1000 1000 1200 N/A - Purge


System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 62-67 <35.0/55.0 Max Fuel


IE

400 250 700 10.0-11.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test


D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 116 Testing Prerequisites
0 986 435 049 Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 668 070 09 87
Test Oil Temperature- 40 C

EM
Engine:- OM668-940
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 56-60 <35.0/55.0 Max Fuel


400 250 700 10.0-12.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 118 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ERAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- OPEL 97300091
Test Oil Temperature- 40 C

EM
Engine:- Z17DTL
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 50-55 <35.0/55.0 Max Fuel


IE

400 250 700 15.0-16.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 119 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 55187290
Test Oil Temperature- 40 C

EM
Engine:- 1.9JTD 8V
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 80-85 <35.0/55.0 Max Fuel


IE

400 250 700 10.0-11.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 121 Testing Prerequisites
0 986 435 051 Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 613 070 03 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-962 / OM612-962
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 70-72 <35.0/55.0 Max Fuel


400 250 700 9.0-10.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test

400 150-250 700 N/A - S.O.I


D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 125 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFL19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- MWM 94 070 46 4 0024
Test Oil Temperature- 40 C

EM
Engine:-
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 80-85 <35.0/55.0 Max Fuel


IE

400 250 700 9.0-10.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 130 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS17/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 13 53 7 789 573
Test Oil Temperature- 40 C

EM
Engine:-
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 52.5-57.5 <35.0/55.0 Max Fuel


400 250 700 9.0-10.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 131 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS17/ZEREK10S TEST OIL: ISO 4113
EXCHANGE: 0 986 435 084 TEST OIL TEMP: 40C
O.E.M. REF: BMW 13 53 7 787 234 SOLENOID RESISTANCE @ 20C - 600m
ENGINE: 30 6 D2 3.0d 110/150/160 KW

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A
- - Leaks

1500 1350 900 83-88 <35.0 55.0 Max Fuel

400 250 700 12-16 <20.0 9.0 Idle

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 135 Testing Prerequisites
0 986 435 085 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 96487862
Test Oil Temperature- 40 C

EM
Engine:- 1.4HDi 8HX/8HZ
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 41-45 <35.0/55.0 Max Fuel


IE

400 250 700 11.0-12.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


N

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI

from nozzle holes. Rail pressure should be 150-200BAR.


ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 136 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFL17/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FORD 3M5Q 9F593 CA
Test Oil Temperature- 40 C

EM
Engine:- 1.6 TDCI
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 47-50 <35.0/55.0 Max Fuel


IE

400 250 700 5.0-6.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 139/140 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 646 070 02 87
Test Oil Temperature- 40 C

EM
Engine:- OM646-982
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 81-86 <35.0/55.0 Max Fuel


400 250 700 11.5-12.5 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 141 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200146357
Test Oil Temperature- 40 C

EM
Engine:- G9U-724 / G9U-754 2.5DCi
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 92-95 <35.0/55.0 Max Fuel


IE

400 250 700 10.0-11.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052 Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 146 Testing Prerequisites
0 986 435 087 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200 238 528
Test Oil Temperature- 40 C

EM
Engine:- F9Q 820
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 64-69 <35.0/55.0 Max Fuel


400 250 700 9.0-10.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 149 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFL17/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 13 53 7 790 630
Test Oil Temperature- 40 C

EM
Engine:- 20 4 D 4 1.8D
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 55-60 <35.0/55.0 Max Fuel


IE

400 250 700 5.0-7.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 156 (155) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZERES20S TEST OIL: ISO 4113

LT
O.E.M. REF: MERCEDES BENZ TEST OIL TEMP: 40C
ENGINE: OM646.951/961 + VARIOUS SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 70-75 <35.0 <55.0 Max Fuel

400 250 700 8-10 <20.0 <9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 158 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFL19/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- VW 057 130 277 L
Test Oil Temperature- 40 C

EM
Engine:- ASE 4.0 TDI
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 75.0-80.0 <35.0/55.0 Max Fuel


IE

400 250 700 8.0-10.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 159 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- OPEL 55192739
Test Oil Temperature- 40 C

EM
Engine:- Z19 DTH
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 95-99 <35.0/55.0 Max Fuel


IE

400 250 700 8.0-9.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 161 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFL17/ZEREA20S TEST OIL: ISO 4113

LT
EXCHANGE: 0 986 435 091 TEST OIL TEMP: 40C
O.E.M. REF: BMW SOLENOID RESISTANCE @ 20C - 600m

S
ENGINE: 204D4, 306D2

EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 97-103 <35.0 55.0 Max Fuel

400 250 700 4-7 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 165 (0 986 435 103) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: VAUXHALL/OPEL TEST OIL TEMP: 40C
ENGINE: 1.9 CDTI SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 87-93 <35.0 <55.0 Max Fuel

400 250 700 8-12 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 166-167 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: MERCEDES BENZ TEST OIL TEMP: 40C
ENGINE: A160, A180, A200 CDI SOLENOID RESISTANCE @ 20C - 600m
B180, B200 CDI

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 62-68 <35.0 <55.0 Max Fuel

400 250 700 7-11 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 168 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- NISSAN 16600 DB 000
Test Oil Temperature- 40 C

EM
Engine:- 1.6 HDi -
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 95-100 <35.0/55.0 Max Fuel


IE

400 250 700 6.0-7.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 169 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZEREK20S TEST OIL: ISO 4113

LT
EXCHANGE: - TEST OIL TEMP: 40C
O.E.M. REF: RENAULT 3.0L SOLENOID RESISTANCE @ 20C - 600m

S
ENGINE: -

EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 112-118 <35.0 55.0 Max Fuel

400 250 700 6-9 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 174 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL21/ZERES20S TEST OIL: ISO 4113

LT
O.E.M. REF: OPEL TEST OIL TEMP: 40C
ENGINE: 1.7 CDTi SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 54-60 <35.0 <55.0 Max Fuel

400 250 700 9-11 <20.0 <9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 175 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPl17/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- OPEL 897 363 812
Test Oil Temperature- 40 C

EM
Engine:- OM648
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
S

1500 1350 900 58-64 <35.0/55.0 Max Fuel


400 250 700 10.0-11.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 177 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 648 070 02 87
Test Oil Temperature- 40 C

EM
Engine:- OM648
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 64-70 <35.0/55.0 Max Fuel


400 250 700 10.0-12.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 181 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZEREAK10S TEST OIL: ISO 4113
O.E.M. REF: MERCEDES SPRINTER/VITO TEST OIL TEMP: 40C
ENGINE: 2.2/2.7L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 64-68 <35.0 <55.0 Max Fuel

400 250 700 10-12 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 183 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- OPEL 93184178
Test Oil Temperature- 40 C

EM
Engine:- Z13 DTH
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 68-72 <35.0/55.0 Max Fuel


IE

400 250 700 7.0-9.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 186/279 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- HYUNDAI 33800 4A100
Test Oil Temperature- 40 C

EM
Engine:- D4CB 2.5Lt
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 88.0-93.0 <35.0/55.0 Max Fuel


IE

400 250 700 8.0-10-0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 187 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 55197875
Test Oil Temperature- 40 C

EM
Engine:- 1.3JTD 8V
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 80-85 <35.0/55.0 Max Fuel


IE

400 250 700 7-9 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 188 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS17/ZERAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1980-H3
Test Oil Temperature- 40 C

EM
Engine:- 1.6 HDi - FORD 1.6 TDCi
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 52-55 <35.0/55.0 Max Fuel
S

400 250 700 8.0-9.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 190 Testing Prerequisites
0 986 435 045 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 611 070 16 87
Test Oil Temperature- 40 C

EM
Engine:- OM611-981 OM644-987
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 73-77 <35.0/55.0 Max Fuel


400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 192 Testing Prerequisites
0 445 110 191 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- 647 070 00 87
Test Oil Temperature- 40 C

EM
Engine:- OM646.982
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 73-76 <35.0/55.0 Max Fuel


400 250 700 12.0-13.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 196 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREAK10S TEST OIL: ISO 4113
O.E.M. REF: MERCEDES BENZ TEST OIL TEMP: 40C
ENGINE: A SERIES, A160/170 CDI SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 57-63 <35.0 <55.0 Max Fuel

400 250 700 8-12 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 201 / 202 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZEREAK10S TEST OIL: ISO 4113

LT
O.E.M. REF: MERCEDES BENZ TEST OIL TEMP: 40C
ENGINE: 2.2L SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 68-72 <35.0 55.0 Max Fuel

400 250 700 8-10 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 206 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 613 070 09 87
Test Oil Temperature- 40 C

EM
Engine:-
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 68-74 <35.0/55.0 Max Fuel


IE

400 250 700 8.0-9.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 209 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFL17/ZEREAK20S TEST OIL: ISO 4113
O.E.M. REF: BMW TEST OIL TEMP: 40C
ENGINE: 118d, 318d 2.0L SOLENOID RESISTANCE @ 20C - 600m
325d, 525d 3.0L

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 80-86 <35.0 <55.0 Max Fuel

400 250 700 9-13 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 212 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: BMW 5 SERIES TEST OIL TEMP: 40C
05/2004>03/2007 SOLENOID RESISTANCE @ 20C - 600m
ENGINE: 2.5L

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 83-88 <35.0 <55.0 Max Fuel

400 250 700 7-10 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 213 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZERAK20S TEST OIL: ISO 4113

LT
EXCHANGE: - TEST OIL TEMP: 40C
O.E.M. REF: FIAT 55192740 SOLENOID RESISTANCE @ 20C - 600m

S
ENGINE: 939 A 3000 2.4JTD 20V

EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 108-113 <35.0 55.0 Max Fuel

400 250 700 5-8 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 215 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS17/ZEREK20S TEST OIL: ISO 4113

LT
EXCHANGE: - TEST OIL TEMP: 40C
O.E.M. REF: 23670-33030 SOLENOID RESISTANCE @ 20C - 600m

S
ENGINE: TOYOTA

EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 44-48 <35.0 55.0 Max Fuel

400 250 700 4-6 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 216 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFL17/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 13 53 7793836
Test Oil Temperature- 40 C

EM
Engine:- 30 6 D2 / 20 4 D4
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 80-85 <35.0/55.0 Max Fuel


400 250 700 8.0-9.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 230 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113

LT
O.E.M. REF: RENAULT/SUZUKI TEST OIL TEMP: 40C
ENGINE: 1.9L, F9Q SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 72-77 <35.0 55.0 Max Fuel

400 250 700 6-9 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 236 TEST PUMP: SUITABLE CR PUMP
0 986 435 145 TEST OIL: ISO 4113
TYPE: CR/IPL19/ZEREK20S TEST OIL TEMP: 40C
O.E.M. REF: HONDA SOLENOID RESISTANCE @ 20C - 600m
ENGINE: 2.2 CDTI

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 60-68 <35.0 <55.0 Max Fuel

400 250 700 10-14 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 237/238 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZERAK20S TEST OIL: ISO 4113
O.E.M. REF: DB 646 070 07 87 TEST OIL TEMP: 40C
ENGINE: OM646-966 SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A
- - Leaks

1500 1350 900 100-110 <35.0 55.0 Max Fuel

400 250 700 12-16 <20.0 9.0 Idle

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 239 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFL17/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1980 H2
Test Oil Temperature- 40 C

EM
Engine:- 9HX 1.6 HDi
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin

1000 1000 1200 N/A - Purge


EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 47-50 <35.0/55.0 Max Fuel


IE

400 250 700 9.0-1.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 243 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT/OPEL 55198218
Test Oil Temperature- 40 C

EM
Engine:- 1.9 CDTI 150 HP
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 95-100 <35.0/55.0 Max Fuel


400 250 700 7.0-9.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 248 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL21/ZERES20S TEST OIL: ISO 4113
O.E.M. REF: IVECO 504088823 TEST OIL TEMP: 40C
ENGINE: - SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 107-112 <35.0 <55.0 Max Fuel

400 250 700 6-8 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

400 400 60 0.2-3.0 - - Pre Injection

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 250 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: FORD RANGER/MAZDZA 4x4 TEST OIL TEMP: 40C
ENGINE: 2.5L TURBO SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A
- - Leaks

1500 1350 900 62-67 <35.0 55.0 Max Fuel

400 250 700 6-9 <20.0 9.0 Idle

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 251 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL21/ZEREZ20S TEST OIL: ISO 4113

LT
O.E.M. REF: IVECO 504088823 TEST OIL TEMP: 40C
ENGINE: - SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 77-82 <35.0 <55.0 Max Fuel

400 250 700 8-10 <20.0 <9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I

- - - - - - Pre Injection
N
LI

Start of Injection
ER

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
M

5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 252 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: PEUGEOT/CITROEN TEST OIL TEMP: 40C
ENGINE: 1.4HDI SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 64-71 <35.0 <55.0 Max Fuel

400 250 700 6-10 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

- - - - - - -

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 258 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: HYUNDAI / KIA TEST OIL TEMP: 40C
ENGINE: 2.0L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 98-102 <35.0 <55.0 Max Fuel

400 250 700 8-11 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 259 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFL17/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 46472233
Test Oil Temperature- 40 C

EM
Engine:- 182 B 4000 1.9 JTD
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 50-55 <35.0/55.0 Max Fuel
S

400 250 700 9.0-10.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D
N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 262 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS17/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: TOYOTA TEST OIL TEMP: 40C
ENGINE: 1.4 D4D SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 42-48 <35.0 <55.0 Max Fuel

400 250 700 5-9 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 263-264 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZEREAK20S TEST OIL: ISO 4113
O.E.M. REF: MERCEDES-BENZ VITO, VIANO TEST OIL TEMP: 40C
ENGINE: 2.1L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 81-86 <35.0 <55.0 Max Fuel

400 250 700 11.5-12.5 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 265 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- NISSAN
Test Oil Temperature- 40 C

EM
Engine:- 2.5
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 95-100 <35.0/55.0 Max Fuel


400 250 700 10.5-12.5 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 266 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS17/ZERAK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 13 53 7785 94
Test Oil Temperature- 40 C

EM
Engine:- 30 6 D1
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
System
EL

2000 1500 1200 N/A - Check for


Leaks
1500 1350 900 69-72 <35.0/55.0 Max Fuel
S

400 250 700 8.0-9.0 <20.0/9.0 Idle


IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
N

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
ER

When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 270 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: VAUXHALL/OPEL/CHEVROLET TEST OIL TEMP: 40C
ENGINE: 2.0 CDTI / CDRI SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 97-105 <35.0 <55.0 Max Fuel

400 250 700 5-7 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 273 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-IVECO 5040887755
Test Oil Temperature- 40 C

EM
Engine:- FIAE 0481F Daily 2.3
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System

2000 1500 1200 N/A - Check for


Leaks
S

1500 1350 900 83-90 <35.0/55.0 Max Fuel


IE

400 250 700 6.0-7.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test


D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 275 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113

LT
O.E.M. REF: HYUNDAI/KIA TEST OIL TEMP: 40C
ENGINE: 2.5L SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 108-112 <35.0 <55.0 Max Fuel

400 250 700 8-10 <20.0 <9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 276 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ZERAK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 55200259
Test Oil Temperature- 40 C

EM
Engine:- 939.A.7000 1.9JTD
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 90-95 <35.0/55.0 Max Fuel


IE

400 250 700 10.0-11.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 279 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- HYUNDAI 33800 4A100
Test Oil Temperature- 40 C

EM
Engine:- D4CB 2.5Lt
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 62-67 <35.0/55.0 Max Fuel


IE

400 250 700 5.0-7.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 280 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200606383
Test Oil Temperature- 40 C

EM
Engine:-
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
EL

1000 1000 1200 N/A - Purge


System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 100-110 <35.0/55.0 Max Fuel


IE

400 250 700 9.0-10.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test


D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 286 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZEREK20S TEST OIL: ISO 4113

LT
EXCHANGE: - TEST OIL TEMP: 40C
O.E.M. REF: - SOLENOID RESISTANCE @ 20C - 600m

S
ENGINE: -

EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 76-80 <35.0 55.0 Max Fuel

400 250 700 9-11 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 289 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREAK20S TEST OIL: ISO 4113
O.E.M. REF: BMW116/8D, 316/8D, X1, MINI TEST OIL TEMP: 40C
ENGINE: 2.0L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 86-92 <35.0 <55.0 Max Fuel

400 250 700 12-16 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 290 (WAS 126) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZEREK10S TEST OIL: ISO 4113

LT
O.E.M. REF: HYUNDAI / KIA TEST OIL TEMP: 40C
ENGINE: 2.0 CRDi SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 69-75 <35.0 <55.0 Max Fuel

400 250 700 5-8 <20.0 <9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 296 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL19/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-RENAULT 8200606383
Test Oil Temperature- 40 C

EM
Engine:-
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System

2000 1500 1200 N/A - Check for


Leaks
S

1500 1350 900 58-62 <35.0/55.0 Max Fuel


IE

400 250 700 8.0-10.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 297 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFL17/ZEREK20S TEST OIL: ISO 4113

LT
EXCHANGE: 0 986 435 150 TEST OIL TEMP: 40C
O.E.M. REF: PEUGEOT/CITROEN SOLENOID RESISTANCE @ 20C - 600m

S
ENGINE: 1.6 HDi

EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 68-72 <35.0 55.0 Max Fuel

400 250 700 6-8 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 298 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREAK20S TEST OIL: ISO 4113
O.E.M. REF: VOLVO V70, V80, TEST OIL TEMP: 40C
ENGINE: 2.4L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 108-116 <35.0 <55.0 Max Fuel

400 250 700 8-10 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 299 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: ALFA/FIAT/LANCIA TEST OIL TEMP: 40C
ENGINE: 2.0L JTD SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 95-100 <35.0 <55.0 Max Fuel

400 250 700 6-9 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 300 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: ALFA ROMEO, FIAT, LANCIA TEST OIL TEMP: 40C
ENGINE: 1.6 JTD SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 87-93 <35.0 <55.0 Max Fuel

400 250 700 8-10 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 308 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL17/ZEREK20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 53208183
Test Oil Temperature- 40 C

EM
Engine:- 939 A 9000 2.4 JTD 20v
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System

2000 1500 1200 N/A - Check for


Leaks
S

1500 1350 900 105-110 <35.0/55.0 Max Fuel


IE

400 250 700 8.0-10.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 110 311 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:-
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 73.0-77.0 <35.0/55.0 Max Fuel


IE

400 250 700 8.0-9.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 319-320 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: HYUNDAI 1.4 & 1.6/KIA 1.6 TEST OIL TEMP: 40C
ENGINE: 1.4CRDI/1.6CRDI SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 80-88 <35.0 <55.0 Max Fuel

400 250 700 6-10 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 327 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: VAUXHALL/OPEL TEST OIL TEMP: 40C
ENGINE: 2.0L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 117-122 <35.0 <55.0 Max Fuel

400 250 700 6-8 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 338 TEST PUMP: SUITABLE CR PUMP
TYPE: CRI 2.2 TEST OIL: ISO 4113

LT
O.E.M. REF: RENAULT TEST OIL TEMP: 40C
ENGINE: - SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 105-110 <35.0 <55.0 Max Fuel

400 250 700 4-7 <20.0 <9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I

400 400 60 0.2-3.5 - - Pre Injection


N
LI

Start of Injection
ER

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
M

5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 340 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: FORD, CITROEN, PEUGEOT TEST OIL TEMP: 40C
ENGINE: 1.6 TDCI, 1.6 HDI SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A
- - Leaks

1500 1350 900 75-82 <35.0 55.0 Max Fuel

400 250 700 6-10 <20.0 9.0 Idle

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 351 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: FORD KA, FIAT PUNTO, LANCIA, TEST OIL TEMP: 40C
ALFA ROMEO MITO SOLENOID RESISTANCE @ 20C - 600m
ENGINE: 1.3 TDCI, 1.3 JTD, 1.3 MULTIJET

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 80-86 <35.0 <55.0 Max Fuel

400 250 700 9-13 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 352-353 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: FORD FOCUS TEST OIL TEMP: 40C
ENGINE: 1.6 TDCI 12/07>12/11 SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 71-77 <35.0 <55.0 Max Fuel

400 250 700 7-11 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 110 369 TEST PUMP: SUITABLE CR PUMP
TYPE: CRI 2.5 TEST OIL: ISO 4113
O.E.M. REF: AUDI/VW/SEAT/SKODA TEST OIL TEMP: 40C
ENGINE: 2.0L TDI SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A - -
Leaks

1500 1350 900 92-97 <35.0 <55.0 Max Fuel

400 250 700 11-14 <20.0 <9.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 375 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113

LT
O.E.M. REF: - TEST OIL TEMP: 40C
ENGINE: - SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 104-109 <35.0 <55.0 Max Fuel

400 250 700 6-8 <20.0 <9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I

400 400 60 0.2-4.0 - - Pre Injection


N
LI

Start of Injection
ER

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
M

5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 110 414 TEST PUMP: SUITABLE CR PUMP
TYPE: CRI 2.5 TEST OIL: ISO 4113

LT
O.E.M. REF: - TEST OIL TEMP: 40C
ENGINE: - SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 78-83 <35.0 <55.0 Max Fuel

400 250 700 10-12 <20.0 <9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I

400 400 40 0.2-4.0 - - Pre Injection


N
LI

Start of Injection
ER

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
M

5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 115 007 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZEREAK50S TEST OIL: ISO 4113

LT
O.E.M. REF: - TEST OIL TEMP: 40C
ENGINE: M9R CAPACITANCE: 2.1-3.1 Uf @ 20C

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables.(T031-3003R)

Attach Bosch return pipe (0 986 612 922).


Switch S3000 to Piezo.
Close protective cover.
ST
SY
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
L
SE

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
IE

- - Check for Leaks


1000 1450 1200 105-115 <40.0 60.0 Max Fuel
D

1000 1450 900 72-82 Mid Range


1000 1450 700 52-62 - - Low Speed
1000 500 700 20-25 Idle
N

400 150-250 700 N/A S.O.I


LI
ER

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
M

Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 115 025 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREAK50S TEST OIL: ISO 4113

LT
O.E.M. REF: PSA TEST OIL TEMP: 40C
ENGINE: 2.2L CAPACITANCE: 2.1-3.1 Uf @ 20C

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).

Attach Bosch return pipe (0 986 612 922).


Switch S3000 to Piezo.
Close protective cover.
ST
SY
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
L
SE

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
IE

- - Check for Leaks


1000 1450 1200 107-117 <40.0 60.0 Max Fuel
D

1000 1450 900 75-84 Mid Range


1000 1450 700 54-60 - - Low Speed
1000 500 700 20-25 Idle
N

400 150-250 700 N/A S.O.I


LI
ER

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
M

Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 115 028 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZEREAK50S TEST OIL: ISO 4113

LT
O.E.M. REF: VW TEST OIL TEMP: 40C
ENGINE: 2.5L CAPACITANCE: 2.1-3.1 Uf @ 20C

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).

Attach Bosch return pipe (0 986 612 922).


Switch S3000 to Piezo.
Close protective cover.
ST
SY
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
L
SE

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
IE

- - Check for Leaks


1000 1450 1200 112-116 <40.0 60.0 Max Fuel
D

1000 1450 900 78-82 Mid Range


1000 1450 700 54-60 - - Low Speed
1000 500 700 22-24 Idle
N

400 150-250 700 N/A S.O.I


LI
ER

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
M

Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 115 042 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREAK50S TEST OIL: ISO 4113
O.E.M. REF: L/ ROVER FREELANDER 2 TD4 TEST OIL TEMP: 40C
ENGINE: 2.2L CAPACITANCE: 2.1-3.1 Uf @ 20C

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.

NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED


OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 98-108 <40.0 60.0 Max Fuel

1000 1450 900 80-86 Mid Range


1000 1450 700 56-63 - - Low Speed

1000 500 700 15-20 Idle


400 150-250 700 N/A S.O.I

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 115 063 (026) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZEREAK50S TEST OIL: ISO 4113
O.E.M. REF: CHRYSLER/JEEP/MERCEDES TEST OIL TEMP: 40C
ENGINE: 3.0L CAPACITANCE: 2.1-3.1 Uf @ 20C

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.

NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED


OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 107-117 <40.0 60.0 Max Fuel
1000 1450 900 75-84 Mid Range
1000 1450 700 54-60 - - Low Speed
1000 500 700 22-27 Idle
400 150-250 700 N/A S.O.I

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 115 068 (069,032,033) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREAK50S TEST OIL: ISO 4113
O.E.M. REF: MERCEDES SPRINTER VITO TEST OIL TEMP: 40C
ENGINE: 2.1L CAPACITANCE: 2.1-3.1 Uf @ 20C

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables.(T031-3201R)
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.

NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED


OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 100-110 <40.0 60.0 Max Fuel
1000 1450 900 65-75 Mid Range
1000 1450 700 45-55 - - Low Speed
1000 500 700 20-25 Idle

400 150-250 700 N/A S.O.I

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 115 070 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113

LT
O.E.M. REF: BMW 3.0 TEST OIL TEMP: 40C
ENGINE: 2.1L CAPACITANCE: 2.1-3.1 Uf @ 20C

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables.(T031-3201R)

Attach Bosch return pipe (0 986 612 922).


Switch S3000 to Piezo.
Close protective cover.
ST
SY
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
L
SE

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
IE

- - Check for Leaks


1000 1450 1200 110-120 <40.0 60.0 Max Fuel
D

1000 1450 900 75-85 Mid Range


1000 1450 700 55-65 - - Low Speed
1000 500 700 22-27 Idle
N

400 150-250 700 N/A S.O.I


LI
ER

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
M

Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 115 078 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFL19/ZEREAK50S TEST OIL: ISO 4113
O.E.M. REF: AUDI A8, VW TEST OIL TEMP: 40C
ENGINE: 3.0 TDI V6 CAPACITANCE: 2.1-3.1 Uf @ 20C

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.

NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED


OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 117-123 <40.0 60.0 Max Fuel

1000 1450 900 78-82 Mid Range


1000 1450 700 58-62 - - Low Speed
1000 500 700 24-28 Idle

400 150-250 700 N/A S.O.I

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 116 001 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREAK60S TEST OIL: ISO 4113
O.E.M. REF: BMW 120D, 320D, 520D, X3 TEST OIL TEMP: 40C
ENGINE: 2.0 L CAPACITANCE: 2.1-3.1 Uf @ 20C

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.

NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED


OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 165-175 <40.0 60.0 Max Fuel
1000 1450 900 78-88 Mid Range

1000 1450 700 57-63 - - Low Speed


1000 500 700 17-23 Idle

400 150-250 700 N/A S.O.I

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 116 022 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFL19/ZEREAK60S TEST OIL: ISO 4113
O.E.M. REF: AUDI/VW TEST OIL TEMP: 40C
ENGINE: 2.7TDI, 3.0TDI CAPACITANCE: 2.1-3.1 Uf @ 20C

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.

NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED


OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 115-125 <40.0 60.0 Max Fuel
1000 1450 900 83-93 Mid Range
1000 1450 700 60-68 - - Low Speed
1000 500 700 12-17 Idle
400 150-250 700 N/A S.O.I

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 116 029 (030) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFL19/ZEREAK65S TEST OIL: ISO 4113
O.E.M. REF: AUDI/SEAT/SKODA/VW TEST OIL TEMP: 40C
ENGINE: 2.0 TDI CAPACITANCE: 2.1-3.1 Uf @ 20C

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.

NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED


OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 103-112 <40.0 60.0 Max Fuel
1000 1450 900 77-84 Mid Range

1000 1450 700 57-63 - - Low Speed


1000 500 700 15-24 Idle

400 150-250 700 N/A S.O.I

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 116 059 (019) TEST PUMP: SUITABLE CR PUMP
TYPE: CR13-18, (019 = CR13.2) TEST OIL: ISO 4113
O.E.M. REF: FIAT DUCATO/IVECO DAILY TEST OIL TEMP: 40C
ENGINE: 3.0L / 2.3-3.0L CAPACITANCE: 2.1-3.1 Uf @ 20C

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.

NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED


OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 105-115 <40.0 60.0 Max Fuel
1000 1450 900 68-76 Mid Range
1000 1450 700 45-53 - - Low Speed
1000 500 700 18-23 Idle
400 150-250 700 N/A S.O.I

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 120 002 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS21/ZIREK10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- IVECO 500313105
Test Oil Temperature- 40 C

EM
Engine:- 8140-43
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 92-97 <35.0/55.0 Max Fuel


IE

400 250 700 16.0-19.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 120 003/004 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPL32ZIRIS10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RVI 50 10 412 093
Test Oil Temperature- 40 C

EM
Engine:- 420DCi 303 Kw >2001
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 150-165 <35.0/55.0 Max Fuel


IE

400 250 700 25.0-28.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 120 007 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFS26/ZIRIS10S TEST OIL: ISO 4113

LT
O.E.M. REF: CDC 4897271 TEST OIL TEMP: 40C
ENGINE: - SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3901.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 82-87 <35.0 55.0 Max Fuel

400 250 700 12-18 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 120 011 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZEREK10S TEST OIL: ISO 4113
O.E.M. REF: IVECO 500371101 TEST OIL TEMP: 40C
ENGINE: F1AE-0481 SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A
- - Leaks

1500 1350 900 70-75 <35.0 55.0 Max Fuel

400 250 700 13-15 <20.0 9.0 Idle

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 120 020 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:- ISB
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 115-125 <35.0/55.0 Max Fuel


IE

400 250 700 12.0-13.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 120 028 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFL26/ZIRIS10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- IVECO 504055805
Test Oil Temperature- 40 C

EM
Engine:- CSC ISB
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System

2000 1500 1200 N/A - Check for


Leaks
S

1500 1350 900 100-110 <35.0/55.0 Max Fuel


400 250 700 12.0-14.0 <20.0/9.0 Idle
IE

2000 1350 Run pump only N/A <12-5/25.0 Seat test


400 150-250 700 N/A - S.O.I
D

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 120 030 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:- QSB
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 155-167 <35.0/55.0 Max Fuel


IE

400 250 700 5.0-7.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 120 036 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK10S TEST OIL: ISO 4113
O.E.M. REF: IVECO DAILY TEST OIL TEMP: 40C
ENGINE: 3.0 L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A
- - Leaks

1500 1350 900 82-87 <35.0 55.0 Max Fuel

400 250 700 8-12 <20.0 9.0 Idle

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 120 040 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL26/ZIRIS10S TEST OIL: ISO 4113

LT
O.E.M. REF: - TEST OIL TEMP: 40C
ENGINE: - SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3901.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 100-110 <35.0 55.0 Max Fuel

400 250 700 8-12 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 120 054 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFl26/ZIRIS20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- IVECO 504091504
Test Oil Temperature- 40 C

EM
Engine:- QSB
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System

2000 1500 1200 N/A - Check for


Leaks
S

1500 1350 900 100-110 <35.0/55.0 Max Fuel


IE

400 250 700 13.0-15.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 120 057 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IFS26/ZIRIS20S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- IVECO 504091505
Test Oil Temperature- 40 C

EM
Engine:- QSB
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 100-110 <35.0/55.0 Max Fuel


IE

400 250 700 15.0-17.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I


N

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
LI

Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
ER

from nozzle holes. Rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow
M

rates are matched through the set.


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 0 445 120 064 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL28/ZIRIS20S TEST OIL: ISO 4113

LT
O.E.M. REF: RENAULT TEST OIL TEMP: 40C
ENGINE: - SOLENOID RESISTANCE @ 20C - 600m

S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3901.
Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for


1000 1000 700 N/A
- - Leaks
SE

1500 1350 900 95-100 <35.0 55.0 Max Fuel

400 250 700 12-14 <20.0 9.0 Idle


IE

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I


N

Start of Injection
LI

1) Stop test bench.


2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.


4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 120 073 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFL19/ZEREK30S TEST OIL: ISO 4113
O.E.M. REF: MITSUBISHI TEST OIL TEMP: 40C
ENGINE: 3.0 L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A
- - Leaks

1500 1350 900 68-72 <35.0 55.0 Max Fuel

400 250 700 12-16 <20.0 9.0 Idle

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 120 098 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL26/ZIRIS20S TEST OIL: ISO 4113
O.E.M. REF: MAN TEST OIL TEMP: 40C
ENGINE: 4.6, 6.9 L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3901.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A
- - Leaks

1500 1350 900 118-125 <35.0 55.0 Max Fuel

400 250 700 22-26 <20.0 9.0 Idle

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM


S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 0 445 120 210 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:- ISB
Solenoid Resistance @ 20C - 600 m

ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
SY
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
1000 1000 1200 N/A - Purge
EL

System
2000 1500 1200 N/A - Check for
Leaks
S

1500 1350 900 75.0-80.0 <35.0/55.0 Max Fuel


IE

400 250 700 10.0-13.0 <20.0/9.0 Idle


2000 1350 Run pump only N/A <12-5/25.0 Seat test
D

400 150-250 700 N/A - S.O.I

Start of Injection
N

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.


Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
LI

400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
from nozzle holes. Rail pressure should be 150-200BAR.
ER

Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
M
S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS


PART No: 0 445 120 217 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL26/ZIRIS20S TEST OIL: ISO 4113
O.E.M. REF: MAN TRUCK TEST OIL TEMP: 40C
ENGINE: 10.5 L SOLENOID RESISTANCE @ 20C - 600m

Remove all washers from injectors.


Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3003.
Close protective cover.

Pump Rail Max Back Leak


Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for


1000 1000 700 N/A
- - Leaks

1500 1350 900 178-188 <35.0 55.0 Max Fuel

400 250 700 12-16 <20.0 9.0 Idle

Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM