TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 029 Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- DB 628 070 01 01 Test Oil Temperature- 40 C Engine:- OM628.960/961 Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 031 Type Designation:- CR/CP3S3/R70/20-789S CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- RENAULT 8200 037 472 Test Oil TemperatureTemperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 T031- 3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5- 2.0
2
1000
500
4.0- 5.0
3
2000
1350
2.5- 3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
3. RESISTANCES Test
Bench Speed - RPM
1
-
2 -
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA Pump Designation:- 0 445 010 033
Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Type Designation:-CR/CP3S3/L70/ 0-8911S Manufacturer I.D.:-
Test Oil Specification- ISO 4113 Test Oil Temperature- 40 C
Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 034 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- VM 3502 2087F Test Oil Temperature- 40 C Engine:- CHRYSLER 2.5CRDI Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
-
20
3.5- 3.7
-
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 039 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- ISUZU 897227 0264 Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 042 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- PSA 1920 EC 96373173 Test Oil Temperature- 40 C Engine:- 8HX / 8HZ Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 045 Type Designation:-CR/CP3S3/R70/20-89S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- BMW 1351 7 787199 Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 047 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- TOYOTA Test Oil Temperature- 40 C Engine:- D-4D 1.4 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 048 Type Designation:- CR/CP3S3/L70/20- 89S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- DB611 070 14 01 Test Oil Temperature- 40 C Engine:- OM646-962/982 Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 052 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- KIA/HYUNDAI 33100-4A000 Engine:- D4CB
Test Oil Temperature- 40 C Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 075 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- RENAULT 8200 108 225 OPEL 9109268 Engine:- 1.9DCI
Test Oil Temperature- 40 C Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 076 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- ISUZU 897227 0264 Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 082 Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- VW 057 130 755 G Test Oil Temperature- 40 C Engine:- AUDI 4.0 ASE Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 084 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- VM 35022103F Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 085 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- TOYOTA Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 086 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- OPEL 97327924 Test Oil Temperature- 40 C Engine:- Z17 DTL/DTH Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 087 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- RENAULT 8200 229 004 Test Oil Temperature- 40 C Engine:- F9Q803/804 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 088 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- TOYOTA 22100-ON010 Test Oil Temperature- 40 C Engine:- D-4D 1.4 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 089 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- PSA 1920 FL FORD3M5Q 9A 543AA Engine:- 9HZ/9HY
Test Oil Temperature- 40 C Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 093 Type Designation:- CR/CP3S3/L70/20- 789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- HONDA 16410RBDE000 Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 096 Type Designation:-CR/CP3S3/L70/20-8911S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- DB 640 070 06 01 Test Oil Temperature- 40 C Engine:- OM640-940/941/942 Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 099 Type Designation:- CR/CP3S3/L70/20- 789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- RENAULT 8200409390 Test Oil Temperature- 40 C Engine:- M9R 760
2.0DCi Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 101 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- KIA/HYUNDAI 33100-4A010 Engine:- D4FA / D4CB
Test Oil Temperature- 40 C Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 102 Type Designation:-
Test Oil Specification- ISO 4113 Manufacturer I.D.:- peu/for/cit/maz Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 104 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- VM 35022098F Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 105 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- TOYOTA 22100-33040 Test Oil Temperature- 40 C Engine:- D-4D INDTV Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 106 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- TOYOTA 22100-33030 Test Oil Temperature- 40 C Engine:- D-4D 1.4 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 112 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- TOYOTA 22100-33011 Test Oil Temperature- 40 C Engine:- D-4D 1.4 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 113 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- TOYOTA 22100-0N010 Test Oil Temperature- 40 C Engine:- D-4D 1.4 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 114 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- TOYOTA 22100-33020 Test Oil Temperature- 40 C Engine:- D-4D 1.4 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 119 Type Designation:-CR/CP3S3/L11 Designation:-CR/CP3S3/L110/30-789S 0/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- VW 057 130 755h Test Oil TemperatureTemperature- 40 C Engine:- AUDI 4.2 BMC Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 T031- 3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5- 2.0
2
1000
500
4.0- 5.0
3
2000
1350
2.5- 3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 120 Type Designation:-CR/CP3S3/L70 Designation:-CR/CP3S3/L70/20-8911S /20-8911S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- DB 640 070 07 01 Test Oil TemperatureTemperature- 40 C Engine:- OM640-940/941/942 OM640-940/941/942 Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 T031- 3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5- 2.0
2
1000
500
4.0- 5.0
3
2000
1350
2.5- 3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 125 Type Designation:-CR/CP3S3/R90/20-89S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- BMW 1351 7 795714 Test Oil Temperature- 40 C Engine:- 204D4 / 306D3 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 126 Type Designation:-CR/CP3S3/R70/20-89S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- BMW 1351 7 795714 Test Oil Temperature- 40 C Engine:- 204D4 / 306D3 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 127 Type Designation:- CR/CP3S3/L70/20- 89S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- DB664 070 00 01 Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 134 Type Designation:- CR/CP3S3/R70/20-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- TOYOTA 22100-ON020 Test Oil Temperature- 40 C Engine:- 1.4 4-D4 Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 141 Type Designation:- CR/CP3S3/L70/20- 789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- HONDA 16790RBDE020 Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 146 Type Designation:-CR/CP3S3/R70/20-89S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- BMW Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 153 Type Designation:- CR/CP3S3/R70/20-8911S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- DB 660 070 0101 Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 168 Type Designation:-CR/CP3S3/L70/20-8911S
Test Oil Specification- ISO 4113 Manufacturer I.D.:Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV. Set S3000 test unit to ‘PCV’ 1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Remove one suction valve cover from fuel pump and fit T016-702 Transfer pressure adaptor and connect to bench pressure gauge. Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
3. RESISTANCES Test 1 2 -
Bench Speed - RPM
-
PCV Resistance
Shut off Valve Resistance
INLET FUEL TEMP °C
2.5- 2.7
23- 24
20
3.5- 3.7
26- 27
40
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 007 Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- iveco Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Condit ions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 015 Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- CDC 3954343 Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Condit ions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 027 Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- MITSUBISHI ME192242 Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 028 Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- MITSUBISHI ME221816 Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Condit ions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 034 Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- MAN 5111103716 Test Oil Temperature- 40 C Engine:- D0836 Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 039 Type Designation:- CR/CP3S3/R110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- 3972815 Test Oil Temperature- 40 C Engine:Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Conditions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 045 Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- CDC 3971529 Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
1. RUNNING IN/LEAK TEST Test
Bench Speed - RPM
Rail Pressure - BAR
Condit ions
Comments
1
350
250
15 Secs
No Unusual noise
2
2000
500
3 Mins
3
2000
1500
No Leaks and No abnormal Temperature rise.
2. Transfer Pressure Test
Bench Speed - RPM
Rail Pressure - BAR
Comments
1
350
250
1.5-2.0
2
1000
500
4.0-5.0
3
2000
1350
2.5-3.0
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer Pressure BAR
S3000 Common Rail Test System
TEST DATA Testing Prerequisites Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 054 Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113 Manufacturer I.D.:- SISU 837069146 Test Oil Temperature- 40 C Engine:Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005 Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3002 to PCV.
