S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
TEST CONDITIONS
PART No:
095000-0360
TEST PUMP:
SUITABLE CR PUMP
TYPE:
970950-0036
TEST OIL:
ISO 4113
O.E.M. REF:
VAUXHALL/OPEL/RENAULT/SAAB
TEST OIL TEMP:
40°C
ENGINE:
3.0L
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
95-100
<60.0
<90.0
Max Fuel
400
250
700
10-13
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
400
150-250
700
N/A
-
S.O.I
-
Comments
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
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:- ref alla148p765
Test Oil Specification- ISO 4113
Manufacturer I.D.:- NISSAN X TRAIL
Test Oil Temperature- 40 C
Engine:- EURO 3
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
S
Injector Designation:- 095000-0510 16600-8H800
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
400
250 1350
400
150-250
700
135-145 20-22
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
900
IE S
2000
EL
Pump Speed RPM
<50.0
Max Fuel
<30.0
Idle
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
TEST CONDITIONS
PART No:
095000-0530
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
TOYOTA LANDCRUISER
TEST OIL TEMP:
40°C
ENGINE:
3.0TD, 1KD-FTV
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
110-120
<60.0
<90.0
Max Fuel
400
250
700
12-16
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
400
150-250
700
N/A
-
S.O.I
-
Comments
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
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:-
Test Oil Temperature- 40 C
Engine:-
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
S
Injector Designation:- 095000-0570
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
400
250 1350
400
150-250
700
75.0-79.0 10-15
<30.0
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
900
IE S
2000
EL
Pump Speed RPM
Max Fuel Idle
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
TEST CONDITIONS
PART No:
095000-0750
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
TOYOTA LANDCRUISER
TEST OIL TEMP:
40°C
ENGINE:
3.0TD, 1KD-FTV
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
110-120
<60.0
<90.0
Max Fuel
400
250
700
12-16
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
400
150-250
700
N/A
-
S.O.I
-
Comments
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
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:- NISSAN PRIMERA
Test Oil Temperature- 40 C
Engine:- EURO 3
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
S
Injector Designation:- 095000-0880 16600-AU600
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
<50.0
Max Fuel
400
250
700
95-105 15-20
<30.0
Idle
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
1350
400
150-250
900
IE S
2000
EL
Pump Speed RPM
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
LT D
TEST DATA Injector Designation:- 095000-0940
Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
S
--
Test Oil Temperature- 40 C
Engine:-
Solenoid Resistance @ 20°C - 600 m
EM
Manufacturer I.D.:- TOYOTA HI-ACE
SY ST
--
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
<50.0
Max Fuel
700
85-95 14-16
<30.0
Idle
Run pump only
N/A
<12-5/25.0
Seat test
N/A
-
S.O.I
250 1350
400
150-250
900
IE S
400 2000
EL
Pump Speed RPM
700
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113 OPEL MERIVA
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:-
S
Injector Designation:- 095000-5080
Engine:-
4EE2 - ISUZU
Pump Speed RPM
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
<50.0
Max Fuel
700
90.0-95.0 10.0-12.0
<30.0
Idle
Run pump only
N/A
<12.5/25.0
Seat test
N/A
-
S.O.I
400
150-250
SY ST
EL
250 1350
900
IE S
400 2000
Solenoid Resistance @ 20°C - 600 m
700
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:- NISSAN X TRAIL
Test Oil Temperature- 40 C
Engine:- EURO 3
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
S
Injector Designation:- 095000-513# AW402-AW4
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
<50.0
Max Fuel
400
250
700
145-160 12-14
<30.0
Idle
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
1350
400
150-250
900
IE S
2000
EL
Pump Speed RPM
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
TEST DATA TEST CONDITIONS
PART No:
095000-5473
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
ISUZU-N SERIES
TEST OIL TEMP:
40°C
ENGINE:
-
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
1000
1500
1350
400
250
2000
1350
400
150-250
Delivery cc/1000
SE L
1000
Pulse Width
Max Back Leak
Comments
cc/1000
cc/min
-
-
Purge System & Check for Leaks
700
N/A
900
98-103
<50.0
<75.0
Max Fuel
700
2-4
<30.0
<12.0
Idle
N/A
<12.5
<25.0
Seat Test
-
S.O.I
IE
Rail Pressure BAR
Run pump only
D
Pump Speed RPM
700
N/A
-
N
SY ST EM
S
LT
D
INJECTOR DATA
M
ER
LI
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 TEST CONDITIONS
PART No:
095000-5600
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
MITSUBISHI L200
TEST OIL TEMP:
40°C
LT
D
INJECTOR DATA
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
1000
1500
1350
400
250
2000
1350
400
150-250
Delivery cc/1000
SE L
1000
Pulse Width
Max Back Leak
Comments
cc/1000
cc/min
-
-
Purge System & Check for Leaks
700
N/A
900
137-142
<50.0
<75.0
Max Fuel
700
12-16
<30.0
<12.0
Idle
N/A
<12.5
<25.0
Seat Test
-
S.O.I
IE
Rail Pressure BAR
Run pump only
D
Pump Speed RPM
700
N/A
-
N
SY ST EM
S
ENGINE:
M
ER
LI
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
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:- NISSAN PATHFINDER
Test Oil Temperature- 40 C
Engine:- YD25
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
S
Injector Designation:- 095000-5650
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
900
180.0-190.0
<50.0
Max Fuel
700
24.0-28.0
<30.0
Idle
Run pump
N/A
<12-5/25.0
Seat test
N/A
-
S.O.I
250 1350
400
150-250
IE S
400 2000
EL
Pump Speed RPM
700
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
TEST DATA TEST CONDITIONS
PART No:
095000-5780
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
MAZDA
TEST OIL TEMP:
40°C
LT
D
INJECTOR DATA
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
1000
1500
1350
400
250
2000
1350
400
150-250
Delivery cc/1000
SE L
1000
Pulse Width
Max Back Leak
Comments
cc/1000
cc/min
-
-
Purge System & Check for Leaks
700
N/A
900
100-110
<50.0
<75.0
Max Fuel
700
9-13
<30.0
<12.0
Idle
N/A
<12.5
<25.0
Seat Test
-
S.O.I
IE
Rail Pressure BAR
Run pump only
D
Pump Speed RPM
700
N/A
-
N
SY ST EM
S
ENGINE:
M
ER
LI
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
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:- FORD TRANSIT
Test Oil Temperature- 40 C
Engine:- PUMA 2.2 EURO 4
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
S
Injector Designation:- 095000-5800 6C1Q-9KJ46
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
<50.0
Max Fuel
400
250
700
100-110 17-20
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
1350
400
150-250
900
IE S
2000
EL
Pump Speed RPM
<30.0
Idle
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
TEST DATA TEST CONDITIONS
PART No:
095000-6021
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
NISSAN X-TRAIL
TEST OIL TEMP:
40°C
ENGINE:
-
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
1000
1000
1500
1350
400
250
2000
1350
400
150-250
700
N/A
400
400
040
2.5-3.0
Max Back Leak
Comments
cc/1000
cc/min
-
-
Purge System & Check for Leaks
N/A
900
87-92
<50.0
<75.0
Max Fuel
700
15-17
<30.0
<12.0
Idle
N/A
<12.5
<25.0
Seat Test
-
-
S.O.I
-
-
Pre Injection
IE
700
Run pump only
D
N
Delivery cc/1000
SE L
Pulse Width
LI
SY ST EM
S
LT
D
INJECTOR DATA
M
ER
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:
095000-6131
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
OPEL
TEST OIL TEMP:
40°C
ENGINE:
1.7 CDTI
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
115-125
<60.0
<90.0
Max Fuel
400
250
700
17-23
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
400
150-250
700
N/A
-
S.O.I
-
Comments
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:
095000-6240
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
NISSAN NAVARA
TEST OIL TEMP:
40°C
ENGINE:
2.5L
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
115-120
<50.0
<75.0
Max Fuel
400
250
700
14-18
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
400
150-250
700
N/A
-
S.O.I
-
Comments
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
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:- NISSAN PATHFINDER
Test Oil Temperature- 40 C
Engine:-
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
S
Injector Designation:- 095000-6250
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
900
190.0-200.0
<50.0
Max Fuel
700
20.0-25.0
<30.0
Idle
Run pump only
N/A
<12.5/25.0
Seat test
N/A
-
S.O.I
250 1350
400
150-250
IE S
400 2000
EL
Pump Speed RPM
700
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
TEST CONDITIONS
PART No:
095000-7060
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
FORD TRANSIT
TEST OIL TEMP:
40°C
ENGINE:
2.4L
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Comments
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
112-120
<50.0
<75.0
Max Fuel
400
250
700
13-19
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
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
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:Engine:-
Test Oil Temperature- 40 C
EM
S
Injector Designation:- 095000-7581
SY ST
Solenoid Resistance @ 20°C -
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
<50.0
Max Fuel
400
250
700
70-72 8-10
<20
Idle
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
1350
400
150-250
900
IE S
2000
EL
Pump Speed RPM
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:Engine:-
Test Oil Temperature- 40 C
EM
S
Injector Designation:- 095000-7610
SY ST
Solenoid Resistance @ 20°C -
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
<50.0
Max Fuel
400
250
700
100 9-12
<30.0
Idle
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
1350
400
150-250
900
IE S
2000
EL
Pump Speed RPM
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
TEST DATA INJECTOR DATA
TEST CONDITIONS
PART No:
095000-7640
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
TOYOTA RAV4, COROLLA VERSO
TEST OIL TEMP:
40°C
ENGINE:
2.2L
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
88-98
<60.0
<90.0
Max Fuel
400
250
700
8-13
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
400
150-250
700
N/A
-
S.O.I
-
Comments
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:
095000-7670
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
TOYOTA
TEST OIL TEMP:
40°C
ENGINE:
D4D 2.0L
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
80-90
<50.0
<75.0
Max Fuel
400
250
700
7-9
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
400
150-250
700
N/A
-
S.O.I
-
Comments
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
LT D
TEST DATA Injector Designation:- 095000-7730 *SIN ON OLD
Test Oil Specification- ISO 4113
S
Type Designation:-
Testing Prerequisites Mount Suitable Test Pump
Test Oil Temperature- 40 C
Engine:-
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
Manufacturer I.D.:-
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
<50.0
Max Fuel
400
250
700
108-112 8-10
<30.0
Idle
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
1350
400
150-250
900
IE S
2000
EL
Pump Speed RPM
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:-
Test Oil Temperature- 40 C
Engine:-
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
S
Injector Designation:- 095000-7780
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
<50.0
Max Fuel
400
250
700
100-110 10-12
<30.0
Idle
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
1350
400
150-250
900
IE S
2000
EL
Pump Speed RPM
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
LT D
TEST DATA Testing Prerequisites Mount Suitable Test Pump
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:-
Test Oil Temperature- 40 C
Engine:-
Solenoid Resistance @ 20°C - 600 m
SY ST
EM
S
Injector Designation:- 095000-7850
Rail Pressure BAR
Pulse Width
Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000
1000
1200
N/A
-
Purge System
2000
1500
1200
N/A
-
Check for Leaks
1500
1350
400
250 1350
400
150-250
700
98.0-103 8.0-10.0
<20.0
Idle
Run pump only
N/A
<12-5/25.0
Seat test
700
N/A
-
S.O.I
900
IE S
2000
EL
Pump Speed RPM
Max Fuel
D
Start of Injection (S.O.I)
M
ER
LI
N
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
TEST CONDITIONS
PART No:
095000-7890
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
SUBARU LEGACY, OUTBACK
TEST OIL TEMP:
40°C
ENGINE:
2.0D
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
125-135
<60.0
<90.0
Max Fuel
400
250
700
14-18
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
400
150-250
700
N/A
-
S.O.I
-
Comments
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:
295050-0010
TEST PUMP:
SUITABLE CR PUMP
TYPE:
-
TEST OIL:
ISO 4113
O.E.M. REF:
MAZDA 3, 6, CX7
TEST OIL TEMP:
40°C
ENGINE:
2.2 L
SOLENOID RESISTANCE @ 20°C - 600m
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure BAR
Pulse Width
1000
1000
1500
Max Back Leak
Delivery cc/1000
cc/1000
cc/min
700
N/A
-
-
Purge System & Check for Leaks
1350
900
155-165
<60.0
<90.0
Max Fuel
400
250
700
13-17
<30.0
<12.0
Idle
2000
1350
Run pump only
N/A
<12.5
<25.0
Seat Test
400
150-250
700
N/A
-
S.O.I
-
Comments
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
