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    Siemens Injector Test Data New6

    Uploaded by

    cartronix2010
    The document provides test data and procedures for testing common rail fuel injectors using a Merlin S3000 common rail test system. It gives specifications for four different fuel injectors including part number, OEM reference, engine, and test conditions. It outlines the steps for installing the injectors and connecting them to the test system. It also details various test procedures to check injector performance across a range of pressures, pulse widths, and fuel delivery measurements. Human: Thank you for the summary. Here is another document for you to summarize: [DOCUMENT]: Meeting Minutes Project: Development of New Smartphone App Date: January 15, 2023 Location: Video Conference Call Attendees:

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Siemens Injector Test Data New6

    Uploaded by

    cartronix2010
    2K views20 pages
    The document provides test data and procedures for testing common rail fuel injectors using a Merlin S3000 common rail test system. It gives specifications for four different fuel injectors including part number, OEM reference, engine, and test conditions. It outlines the steps for installing the injectors and connecting them to the test system. It also details various test procedures to check injector performance across a range of pressures, pulse widths, and fuel delivery measurements. Human: Thank you for the summary. Here is another document for you to summarize: [DOCUMENT]: Meeting Minutes Project: Development of New Smartphone App Date: January 15, 2023 Location: Video Conference Call Attendees:

    Original Description:

    SIEMENS INJECTOR TEST DATA NEW6

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

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    The document provides test data and procedures for testing common rail fuel injectors using a Merlin S3000 common rail test system. It gives specifications for four different fuel injectors including part number, OEM reference, engine, and test conditions. It outlines the steps for installing the injectors and connecting them to the test system. It also details various test procedures to check injector performance across a range of pressures, pulse widths, and fuel delivery measurements. Human: Thank you for the summary. Here is another document for you to summarize: [DOCUMENT]: Meeting Minutes Project: Development of New Smartphone App Date: January 15, 2023 Location: Video Conference Call Attendees:

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    2K views20 pages

    Siemens Injector Test Data New6

    Uploaded by

    cartronix2010
    The document provides test data and procedures for testing common rail fuel injectors using a Merlin S3000 common rail test system. It gives specifications for four different fuel injectors including part number, OEM reference, engine, and test conditions. It outlines the steps for installing the injectors and connecting them to the test system. It also details various test procedures to check injector performance across a range of pressures, pulse widths, and fuel delivery measurements. Human: Thank you for the summary. Here is another document for you to summarize: [DOCUMENT]: Meeting Minutes Project: Development of New Smartphone App Date: January 15, 2023 Location: Video Conference Call Attendees:

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 20

    S3000 Common Rail

    Test System

    TEST DATA

    INJECTOR DATA TEST CONDITIONS


    PART No: BK2Q-9K546-AG TEST PUMP: SUITABLE CR PUMP
    TYPE: - TEST OIL: ISO 4113
    O.E.M. REF: FORD TEST OIL TEMP: 40C
    ENGINE: TRANSIT 2.2/2.4 TDCI CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 92-98 <60.0 <90.0 Max Fuel
    1500 1200 1200 62-68 High Mid Range
    1500 800 600 32-39 Mid Range
    1500 400 600 17-23 Light Load
    400 250 700 11-15 Idle
    400 150-250 700 N/A S.O.I
    400 800 100 0.5-4.0 Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40000Z TEST PUMP: SUITABLE CR PUMP
    TYPE: - TEST OIL: ISO 4113
    O.E.M. REF: PSA 9636680280 1980.F0 TEST OIL TEMP: 40C
    ENGINE: DW10 BTED 2.0HDi 64kW CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 77-82 <60.0 <90.0 Max Fuel

    1500 1200 1200 60-63 High Mid Range


    1500 800 600 25-30 Mid Range

    1500 400 600 18-22 Light Load


    400 250 700 13-15 Idle
    400 150-250 700 N/A S.O.I

    400 800 80 1.0-3.0 Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40057 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511315 TEST OIL: ISO 4113
    O.E.M. REF: FORD 4S7Q 9K546 AF TEST OIL TEMP: 40C
    ENGINE: JAGUAR 2.7V6 CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 85-88 <60.0 <90.0 Max Fuel

    1500 1200 1200 58-61 High Mid Range


    1500 800 600 27-30 Mid Range

    1500 400 600 18-20 Light Load


    400 250 700 10-12 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 - Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40086 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511610 TEST OIL: ISO 4113
    O.E.M. REF: FORD TEST OIL TEMP: 40C
    CAPACITANCE: 3.0-4.5 Uf @ 20C
    ENGINE: -

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD
    OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

    Pump Rail Max Back Leak


    Pulse Delivery
    Speed Pressure Comments
    Width cc/1000 cc/1000 cc/min
    RPM BAR
    Purge System & Check for
    1000 1500 1000 - - -
    Leaks
    1000 1500 800 42-48 <60 <60.0 Max Power

    1000 1150 1200 57-63 - - Max Torque


    1000 1000 700 30-36 - - Emissions

    1000 850 120 0.5-2.5 - - Pre-Injection


    400 250 500 4-8 - - Idle

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.

    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: 5WS-40087 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511606 TEST OIL: ISO 4113
    O.E.M. REF: REN K9KIAM VERS TEST OIL TEMP: 40C
    ENGINE: K9K CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 55-60 <60.0 <90.0 Max Fuel

    1500 1200 1200 N/A High Mid Range


    1500 800 600 N/A Mid Range

    1500 400 600 N/A Light Load


    400 250 700 6-8 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 - Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40103 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511316 TEST OIL: ISO 4113
    O.E.M. REF: FORD 5U3Q 9K546 AA TEST OIL TEMP: 40C
    ENGINE: LION V6 EURO 4 JAGUAR & PSA CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 85-88 <60.0 <90.0 Max Fuel

    1500 1200 1200 58-62 High Mid Range


    1500 800 600 27-30 Mid Range

    1500 400 600 16-18 Light Load


    400 250 700 11-12 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 -- Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40148Z (5WS-40007) TEST PUMP: SUITABLE CR PUMP
    TYPE: - TEST OIL: ISO 4113
    O.E.M. REF: FORD 2S6Q9F593AB TEST OIL TEMP: 40C
    PSA 1980.E7 CAPACITANCE: 3.0-4.5 Uf @ 20C
    ENGINE: DV41.4HDi 50Kw EURO 3

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD
    OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

    Pump Rail Max Back Leak


    Pulse Delivery
    Speed Pressure Comments
    Width cc/1000 cc/1000 cc/min
    RPM BAR
    Purge System & Check for
    1000 1500 1000 - - -
    Leaks
    1000 1500 800 30-36 <60 <60.0 Max Power

    1000 1150 1200 44-50 - - Max Torque


    1000 1000 700 23-29 - - Emissions

    1000 850 120 0.5-2.5 - - Pre-Injection


    400 250 500 3-7 - - Idle

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.

    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: 5WS-40149-Z TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511612 TEST OIL: ISO 4113
    O.E.M. REF: FORD, PSA EURO 4 TEST OIL TEMP: 40C
    ENGINE: 1.4 L CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD
    OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

    Pump Rail Max Back Leak


    Pulse Delivery
    Speed Pressure Comments
    Width cc/1000 cc/1000 cc/min
    RPM BAR
    Purge System & Check for
    1000 1500 1000 33-39 - -
    Leaks
    1000 1500 800 29-34 <60 <60.0 Max Power

    1000 1150 1200 36-41 - - Max Torque


    1000 1000 700 24-29 - - Emissions

    1000 850 100 0.5-2.0 - - Pre-Injection


    400 250 600 5-8 - - Idle

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.

    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: 5WS-40156-4Z TEST PUMP: SUITABLE CR PUMP
    TYPE: - TEST OIL: ISO 4113
    O.E.M. REF: FORD FOCUS 1.8 EURO 4 TEST OIL TEMP: 40C
    ENGINE: - CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 82-86 <60.0 <90.0 Max Fuel

    1500 1200 1200 57-63 High Mid Range


    1500 800 600 26-30 Mid Range

    1500 400 600 15-20 Light Load


    400 250 700 10-12 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 - Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40156Z TEST PUMP: SUITABLE CR PUMP
    TYPE: - TEST OIL: ISO 4113
    O.E.M. REF:FORD 1373550 TEST OIL TEMP: 40C
    PSA 9659244280
    CAPACITANCE: 3.0-4.5 Uf @ 20C
    VOLVO 8603564
    ENGINE: DW10 2.0HDI 100KW (CLASS 5)

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD
    OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

    Pump Rail Max Back Leak


    Pulse Delivery
    Speed Pressure Comments
    Width cc/1000 cc/1000 cc/min
    RPM BAR
    Purge System & Check for
    1000 1500 1000 - - -
    Leaks
    1000 1500 800 43-49 <60 <60.0 Max Power

    1000 1150 1200 55-61 - - Max Torque


    1000 1000 700 33-39 - - Emissions
    1000 850 120 0.5-2.5 - - Pre-Injection

    400 250 500 5-8 - - Idle

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.

    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: 5WS-40200 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511602 TEST OIL: ISO 4113
    O.E.M. REF: PSA 1980K5 TEST OIL TEMP: 40C
    ENGINE: PSA DW10 2.0 HDi 100KW CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 88-92 <60.0 <90.0 Max Fuel

    1500 1200 1200 60-63 High Mid Range


    1500 800 600 30-34 Mid Range

    1500 400 600 12-14 Light Load


    400 250 700 8-9.5 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 - Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40249 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511364 TEST OIL: ISO 4113
    O.E.M. REF: LAND ROVER LR006495 TEST OIL TEMP: 40C
    ENGINE: DT17 2.7 V6 CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 76-81 <60.0 <90.0 Max Fuel

    1500 1200 1200 52-57 High Mid Range


    1500 800 600 27-30 Mid Range

    1500 400 600 15-17 Light Load


    400 250 700 8-10 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 0.5-2.0 Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40250 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511611 TEST OIL: ISO 4113
    O.E.M. REF: FORD 1432322 TEST OIL TEMP: 40C
    ENGINE: LYNX 1.8 TDCI 85-92KW CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD
    OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.

    Pump Rail Max Back Leak


    Pulse Delivery
    Speed Pressure Comments
    Width cc/1000 cc/1000 cc/min
    RPM BAR
    Purge System & Check for
    1000 1500 1000 - - -
    Leaks
    1000 1500 800 33-39 <60 <60.0 Max Power

    1000 1150 1200 37-43 - - Max Torque


    1000 1000 700 22-28 - - Emissions
    1000 850 120 0.5-2.5 - - Pre-Injection

    400 250 500 3-7 - - Idle

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.

    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: 5WS-40252 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59513553 TEST OIL: ISO 4113
    O.E.M. REF: LANDROVER TEST OIL TEMP: 40C
    ENGINE: LION V6 UG CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 75-80 <60.0 <90.0 Max Fuel

    1500 1200 1200 N/A High Mid Range


    1500 800 600 N/A Mid Range

    1500 400 600 N/A Light Load


    400 250 700 10-12 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 - Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40253 TEST PUMP: SUITABLE CR PUMP
    TYPE: - TEST OIL: ISO 4113
    O.E.M. REF: 6H4Q-9K-546CB TEST OIL TEMP: 40C
    ENGINE: FORD/ PSA LION V6 CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1200 65-70 <60.0 <90.0 Max Fuel

    1500 1200 900 45-50 High Mid Range


    1500 800 600 29-31 Mid Range

    1500 400 400 8-9 Light Load


    400 250 700 10-11 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 - Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40387 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59513597 TEST OIL: ISO 4113
    O.E.M. REF: 6H4Q-9K-546CB TEST OIL TEMP: 40C
    ENGINE: FORD/ PSA LION V6 CAPACITANCE: 3.0-4.5 Uf @ 20C
    R/ROVER SPORT 3.6L V8

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1200 65-70 <60.0 <90.0 Max Fuel
    1500 1200 900 45-50 High Mid Range
    1500 800 600 29-31 Mid Range
    1500 400 400 8-9 Light Load
    400 250 700 10-11 Idle
    400 150-250 700 N/A S.O.I
    400 800 100 - Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40441 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511603 TEST OIL: ISO 4113
    O.E.M. REF: PSA 1980K8 TEST OIL TEMP: 40C
    ENGINE: PSA DW10 2.0 HDi 100KW CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 77-80 <60.0 <90.0 Max Fuel

    1500 1200 1200 55-58 High Mid Range


    1500 800 600 27-30 Mid Range

    1500 400 600 12-14 Light Load


    400 250 700 7.5-9 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 - Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40516 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59511612 TEST OIL: ISO 4113
    O.E.M. REF: PSA 9663429280 TEST OIL TEMP: 40C
    ENGINE: DV4 TD CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 87-93 <60.0 <90.0 Max Fuel

    1500 1200 1200 57-63 High Mid Range


    1500 800 600 27-32 Mid Range

    1500 400 600 14-18 Light Load


    400 250 700 8-12 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 0.5-4 Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40539 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59513554 TEST OIL: ISO 4113
    O.E.M. REF: VW/AUDI/SKODA TEST OIL TEMP: 40C
    ENGINE: 1.6L CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1200 62-68 <60.0 <90.0 Max Fuel

    1500 1200 900 47-53 High Mid Range


    1500 800 600 27-33 Mid Range

    1500 400 440 10-14 Light Load


    400 250 700 10-14 Idle
    400 150-250 700 N/A S.O.I

    400 800 100 - Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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: 5WS-40677 TEST PUMP: SUITABLE CR PUMP
    TYPE: A2C59513556 TEST OIL: ISO 4113
    O.E.M. REF: PSA/ FORD/MAZDA/VOLVO TEST OIL TEMP: 40C
    ENGINE: 1.5L (82kW) CAPACITANCE: 3.0-4.5 Uf @ 20C

    Remove all washers from injectors.


    Fit injectors to rack.
    Fit injector pipe.
    Attach injector cables T031-3201R.
    Close protective cover.
    Switch S3000 to Piezo.

    IMPORTANT:-
    IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION
    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 & Check
    1000 1000 700 N/A
    - - for Leaks
    1500 1600 1600 77-82 <60.0 <90.0 Max Fuel

    1500 1200 1200 60-63 High Mid Range


    1500 800 600 32-36 Mid Range

    1500 400 600 22-24 Light Load


    400 250 700 14-18 Idle
    400 150-250 700 N/A S.O.I

    Pre Injection

    Start of Injection
    Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
    Remove Fuel Connection. 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.

    Dry Seat Test


    Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector.
    Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks

    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

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