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Bosch Pump Test Plans 4 Web 3232
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Eduardo Alvarez HuizaCopyright:
Available Formats
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 002
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 1S
Manufacturer I.D.:- FIAT 4645 2567
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
100
300
560/56
500
300
600/300
1000
500
600/600
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
540/540
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 003
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 1S
Manufacturer I.D.:- FIAT 4643 2242
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
100
300
560/56
500
300
600/300
1000
500
600/600
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
540/540
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 006
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 1S
Manufacturer I.D.:- FIAT 4652 2786
EM
Test Oil Temperature- 40 C
Engine:- 185A 6 000 2.4JTD
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
350
2000
2000
Rail Pressure - BAR
Conditions
Comments
250
15 Secs
No Unusual noise
500
3 Mins
EL
Bench Speed - RPM
IE
S
Test
1500
No Leaks and
No abnormal
Temperature rise.
2. FUEL DELIVERY
Test
Rail Pressure - BAR
100
300
560/56
500
300
600/300
1000
500
600/600
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Comments
Delivery
Mm3st/ccmin
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
540/540
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 007
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:-
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
Mm3st/ccmin
100
300
540/54
500
300
510/225
1000
500
510/510
1000
1000
340/340
1000
1000
2000
1350
ER
M
Rail Pressure - BAR
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
540/540
510/1020
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 008
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:-
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031-3051 to Fuel Pump.
Connect Fuel Pump Cable T031-3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
350
2000
2000
Rail Pressure - BAR
Conditions
Comments
250
15 Secs
No Unusual noise
500
3 Mins
EL
Bench Speed - RPM
IE
S
Test
1500
No Leaks and
No abnormal
Temperature rise.
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
100
300
500/50
500
300
550/275
1000
500
550/550
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
500/500
550/1100
3. RESISTANCES
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
Test
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R70/10- 1S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- BMW 13 51 2 247 798
Pump Designation:- 0 445 010 009
Engine:- 30 6 D1
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
100
300
500/50
500
300
640/320
1000
500
650/650
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
3. RESISTANCES
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
580/580
600/1200
Test
Bench Speed - RPM
PCV Resistance
Shut off Valve
Resistance
INLET FUEL
TEMP C
2.5-2.7
20
3.5-3.7
40
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 010
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 16S
Manufacturer I.D.:- PSA 1920 CY
EM
Test Oil Temperature- 40 C
Engine:- PSA RHY/RHZ 2.0 HDi
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
Mm3st/ccmin
100
300
560/56
500
300
600/300
1000
500
600/600
1000
500
Activate Aux
Button
>400/400
1000
1000
Max 10% less
than 3
More Than
540/540
2000
1350
ER
M
Rail Pressure - BAR
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
MERLIN S3000 COMMON RAIL TEST SYSTEM
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 011
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:-
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
Mm3st/ccmin
500
300
510/255
1000
500
510/510
1000
500
Activate Aux
Button
n/a
1000
1000
Max 10% less
than 3
More Than
460/460
2000
1350
ER
M
Rail Pressure - BAR
Bench Speed - RPM
LI
Test
2. FUEL DELIVERY
MERLIN S3000 COMMON RAIL TEST SYSTEM
510/1020
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 013
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:-
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031-3051 to Fuel Pump.
Connect Fuel Pump Cable T031-3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
350
2000
2000
Rail Pressure - BAR
Conditions
Comments
250
15 Secs
No Unusual noise
500
3 Mins
EL
Bench Speed - RPM
IE
S
Test
1500
No Leaks and
No abnormal
Temperature rise.
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
100
300
500/50
500
300
550/275
1000
500
550/550
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
500/500
550/1100
3. RESISTANCES
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
Test
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 1S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- RENAULT 7700101016
Pump Designation:- 0 445 010 018
Direction of Rotation - R
SY
ST
Engine:- F9Q- 732 1.9 DCi
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
350
2000
2000
Rail Pressure - BAR
Conditions
Comments
250
15 Secs
No Unusual noise
500
3 Mins
EL
Bench Speed - RPM
IE
S
Test
1500
No Leaks and
No abnormal
Temperature rise.
2. FUEL DELIVERY
Test
Rail Pressure - BAR
100
300
560/56
500
300
600/300
1000
500
600/600
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Comments
Delivery
mm3st/ccmin
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
540/540
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 019
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1K3/L70/10- 6S
Manufacturer I.D.:- DB 612 070 00 01
EM
Test Oil Temperature- 40 C
Engine:- OM612- 961/962/963/967
SY
ST
Direction of Rotation - L
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Rail Pressure - BAR
Comments
Delivery
mm3st/ccmin
100
300
500/50
500
300
640/320
1000
500
650/650
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
580/580
600/1200
3. RESISTANCES
Bench Speed - RPM
PCV Resistance
Shut off Valve
Resistance
INLET FUEL
TEMP C
2.5-2.7
20
3.5-3.7
40
ER
LI
IE
S
EL
SY
ST
EM
LT
D
Test
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 021
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R70/10- 16S
Manufacturer I.D.:- PSA 1920 AL
EM
Test Oil Temperature- 40 C
Engine:- PSA 4HX /RHW 2.2 HDi
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
mm3st/ccmin
300
500/50
500
300
640/320
1000
500
650/650
1000
500
Activate Aux
Button
>420/420
1000
1000
Max 10% less
than 3
More Than
580/580
2000
1350
ER
M
Rail Pressure - BAR
100
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
MERLIN S3000 COMMON RAIL TEST SYSTEM
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 024
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:-
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
Direction of Rotation - L
Remove injector pipes from test rail and blank off with T031-3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031-3051 to Fuel Pump.
Connect Fuel Pump Cable T031-3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
350
2000
2000
Rail Pressure - BAR
Conditions
Comments
250
15 Secs
No Unusual noise
500
3 Mins
EL
Bench Speed - RPM
IE
S
Test
1500
No Leaks and
No abnormal
Temperature rise.
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
100
300
500/50
500
300
550/275
1000
500
550/550
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
500/500
550/1100
3. RESISTANCES
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
Test
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/L70/10- 1S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- RENAULT 8200 010 076
Pump Designation:- 0 445 010 028
Engine:- G9T- 710 2.2DCi
SY
ST
Direction of Rotation - L
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Rail Pressure - BAR
Comments
Delivery
mm3st/ccmin
100
300
500/50
500
300
640/320
1000
500
650/650
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
580/580
600/1200
3. RESISTANCES
Bench Speed - RPM
PCV Resistance
Shut off Valve
Resistance
INLET FUEL
TEMP C
2.5-2.7
20
3.5-3.7
40
ER
LI
IE
S
EL
SY
ST
EM
LT
D
Test
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 029
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L110/30- 789S
Manufacturer I.D.:- DB 628 070 01 01
EM
Test Oil Temperature- 40 C
Engine:- OM628.960/961
SY
ST
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.
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Comments
Delivery
mm3st/ccmin
Max 10% less
than 3
LT
D
970/97
More Than
950/950
1000/2000
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
SY
ST
EM
3. RESISTANCES
3.2-3.6
40
4. SCV Operation
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Cm/1000
NOM
Pump Drv 100%
1100/1100
NOM
Pump Drv 50%
Nil
ER
LI
IE
S
Test
EL
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 030
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1K3/L70/10- 6S
Manufacturer I.D.:- DB 612 070 01 01
EM
Test Oil Temperature- 40 C
Engine:- OM612- 981
SY
ST
Direction of Rotation - L
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV And shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
mm3st/ccmin
100
300
500/50
500
300
640/320
1000
500
650/650
1000
500
Activate Aux
Button
<420/420
1000
1000
Max 10% less
than 3
More Than
580/580
2000
1350
ER
M
Rail Pressure - BAR
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
MERLIN S3000 COMMON RAIL TEST SYSTEM
600/1200
3. RESISTANCES
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
Test
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- RENAULT 8200 037 472
Pump Designation:- 0 445 010 031
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv
50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 032
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1K3/L70/10- 6S
Manufacturer I.D.:- DB 612 070 02 01
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
Direction of Rotation - L
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV And shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
mm3st/ccmin
100
300
500/50
500
300
640/320
1000
500
650/650
1000
500
Activate Aux
Button
<420/420
1000
1000
Max 10% less
than 3
More Than
580/580
2000
1350
ER
M
Rail Pressure - BAR
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
MERLIN S3000 COMMON RAIL TEST SYSTEM
600/1200
3. RESISTANCES
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
Test
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
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
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
Bench Speed - RPM
600/1200
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 034
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 789S
Manufacturer I.D.:- VM 3502 2087F
EM
Test Oil Temperature- 40 C
Engine:- CHRYSLER 2.5CRDI
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 038
Type Designation:- CR/CP1K3/R70/10S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- HYUNDAI 33100 27000
Engine:- D4EA
SY
ST
Direction of Rotation - R
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Rail Pressure - BAR
Comments
Delivery
mm3st/ccmin
100
300
500/50
500
300
640/320
1000
500
650/650
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
580/580
600/1200
3. RESISTANCES
Bench Speed - RPM
PCV Resistance
Shut off Valve
Resistance
INLET FUEL
TEMP C
2.5-2.7
20
3.5-3.7
40
ER
LI
IE
S
EL
SY
ST
EM
LT
D
Test
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- ISUZU 897227 0264
Pump Designation:- 0 445 010 039
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- PSA 1920 EC 96373173
Pump Designation:- 0 445 010 042
Engine:- 8HX / 8HZ
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 89S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- BMW 1351 7 787199
Pump Designation:- 0 445 010 045
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 046
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 16S
Manufacturer I.D.:- PSA 1920 EA
EM
Test Oil Temperature- 40 C
Engine:- PSA RHY/RHS 2.0 HDi
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
mm3st/ccmin
100
300
560/56
500
300
600/300
1000
500
600/600
1000
500
Activate Aux
Button
>400/400
1000
1000
Max 10% less
than 3
More Than
540/540
2000
1350
ER
M
Rail Pressure - BAR
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
MERLIN S3000 COMMON RAIL TEST SYSTEM
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 047
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 789S
Manufacturer I.D.:- TOYOTA
EM
Test Oil Temperature- 40 C
Engine:- D- 4D 1.4
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv
50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 048
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L70/20- 89S
Manufacturer I.D.:- DB611 070 14 01
EM
Test Oil Temperature- 40 C
Engine:- OM646- 962/982
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 052
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 789S
Manufacturer I.D.:- KIA/HYUNDAI
33100- 4A000
Engine:- D4CB
EM
Test Oil Temperature- 40 C
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
Mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 071
Type Designation:-
Test Oil Specification- ISO 4113
Manufacturer I.D.:-
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
Mm3st/ccmin
100
300
540/54
500
300
510/225
1000
500
510/510
1000
1000
340/340
1000
1000
2000
1350
ER
M
Rail Pressure - BAR
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
Max 10% less
than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
540/540
510/1020
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 072
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 1S
Manufacturer I.D.:- LANCIA 75301003
EM
Test Oil Temperature- 40 C
Engine:- 841 M 000 THESIS 2.4 JTD
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
350
2000
2000
Rail Pressure - BAR
Conditions
Comments
250
15 Secs
No Unusual noise
500
3 Mins
EL
Bench Speed - RPM
IE
S
Test
1500
No Leaks and
No abnormal
Temperature rise.
2. FUEL DELIVERY
Test
Rail Pressure - BAR
100
300
560/56
500
300
600/300
1000
500
600/600
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Comments
Delivery
mm3st/ccmin
Max 10%
less than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
540/540
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Direction of Rotation - R
SY
ST
Manufacturer I.D.:- RENAULT 8200 108 225
OPEL 9109268
Engine:- 1.9DCI
Type Designation:- CR/CP3S3/R70/20- 789S
EM
Pump Designation:- 0 445 010 075
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
Mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv
50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- ISUZU 897227 0264
Pump Designation:- 0 445 010 076
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv
50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 082
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L110/30- 789S
Manufacturer I.D.:- VW 057 130 755 G
EM
Test Oil Temperature- 40 C
Engine:- AUDI 4.0 ASE
SY
ST
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.
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Comments
Delivery
Mm3st/ccmin
Max 10% less
than 3
LT
D
970/97
More Than
950/950
1000/2000
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
SY
ST
EM
3. RESISTANCES
3.2-3.6
40
4. SCV Operation
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv
50%
Nil
ER
LI
IE
S
Test
EL
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 084
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 789S
Manufacturer I.D.:- VM 35022103F
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
Mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10%
less than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 085
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 789S
Manufacturer I.D.:- TOYOTA
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv
50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 086
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 789S
Manufacturer I.D.:- OPEL 97327924
EM
Test Oil Temperature- 40 C
Engine:- Z17 DTL/DTH
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
Mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- RENAULT 8200 229 004
Pump Designation:- 0 445 010 087
Engine:- F9Q803/804
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv
50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- TOYOTA 22100- ON010
Pump Designation:- 0 445 010 088
Engine:- D- 4D 1.4
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Direction of Rotation - R
SY
ST
Manufacturer I.D.:- PSA 1920 FL
FORD3M5Q 9A 543AA
Engine:- 9HZ/9HY
Type Designation:- CR/CP3S3/R70/20- 789S
EM
Pump Designation:- 0 445 010 089
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
Bench Speed - RPM
600/1200
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- HONDA 16410RBDE000
Pump Designation:- 0 445 010 093
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 096
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L70/20- 8911S
Manufacturer I.D.:- DB 640 070 06 01
EM
Test Oil Temperature- 40 C
Engine:- OM640- 940/941/942
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
Bench Speed - RPM
600/1200
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- RENAULT 8200409390
Pump Designation:- 0 445 010 099
2.0DCi
Direction of Rotation - L
SY
ST
Engine:- M9R 760
LT
D
TEST DATA
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 101
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 789S
Manufacturer I.D.:- KIA/HYUNDAI
33100- 4A010
Engine:- D4FA / D4CB
EM
Test Oil Temperature- 40 C
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
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
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv
50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 104
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 789S
Manufacturer I.D.:- VM 35022098F
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv
50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- TOYOTA 22100- 33040
Pump Designation:- 0 445 010 105
Engine:- D- 4D INDTV
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10%
less than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- TOYOTA 22100- 33030
Pump Designation:- 0 445 010 106
Engine:- D- 4D 1.4
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- TOYOTA 22100- 33011
Pump Designation:- 0 445 010 112
Engine:- D- 4D 1.4
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- TOYOTA 22100- 0N010
Pump Designation:- 0 445 010 113
Engine:- D- 4D 1.4
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
Bench Speed - RPM
600/1200
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv
50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- TOYOTA 22100- 33020
Pump Designation:- 0 445 010 114
Engine:- D- 4D 1.4
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 119
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L110/30- 789S
Manufacturer I.D.:- VW 057 130 755h
EM
Test Oil Temperature- 40 C
Engine:- AUDI 4.2 BMC
SY
ST
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.
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Comments
Delivery
mm3st/ccmin
Max 10% less
than 3
LT
D
970/97
More Than
950/950
1000/2000
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
SY
ST
EM
3. RESISTANCES
3.2-3.6
40
4. SCV Operation
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv
50%
Nil
ER
LI
IE
S
Test
EL
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 120
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L70/20- 8911S
Manufacturer I.D.:- DB 640 070 07 01
EM
Test Oil Temperature- 40 C
Engine:- OM640- 940/941/942
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
Bench Speed - RPM
600/1200
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R90/20- 89S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- BMW 1351 7 795714
Pump Designation:- 0 445 010 125
Engine:- 204D4 / 306D3
SY
ST
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
Test
Bench Speed - RPM
350
2
3
EL
1. RUNNING IN/LEAK TEST
Conditions
Comments
250
15 Secs
No Unusual noise
2000
500
3 Mins
2000
1500
No Leaks and
No abnormal
Temperature rise.
IE
S
Rail Pressure - BAR
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
800/800
Max 10% less
than 3
More Than
720/720
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
800/800
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 89S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- BMW 1351 7 795714
Pump Designation:- 0 445 010 126
Engine:- 204D4 / 306D3
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 127
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L70/20- 89S
Manufacturer I.D.:- DB664 070 00 01
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 132
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 1S
Manufacturer I.D.:- PSA 1920 JE
EM
Test Oil Temperature- 40 C
Engine:- RHY 2.0 HDi
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
350
2000
2000
Rail Pressure - BAR
Conditions
Comments
250
15 Secs
No Unusual noise
500
3 Mins
EL
Bench Speed - RPM
IE
S
Test
1500
No Leaks and
No abnormal
Temperature rise.
2. FUEL DELIVERY
Test
Rail Pressure - BAR
100
300
560/56
500
300
600/300
1000
500
600/600
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Comments
Delivery
mm3st/ccmin
Max 10%
less than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
540/540
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- TOYOTA 22100- ON020
Pump Designation:- 0 445 010 134
Engine:- 1.4 4- D4
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- HONDA 16790RBDE020
Pump Designation:- 0 445 010 141
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10%
less than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 146
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 89S
Manufacturer I.D.:- BMW
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10%
less than 3
More Than
580/580
Bench Speed - RPM
600/1200
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 153
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R70/20- 8911S
Manufacturer I.D.:- DB 660 070 0101
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 162
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 16S
Manufacturer I.D.:- PSA 1920 CY
EM
Test Oil Temperature- 40 C
Engine:- PSA RHY/RHZ 2.0 HDi
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
mm3st/ccmin
100
300
560/56
500
300
600/300
1000
500
600/600
1000
500
Activate Aux
Button
>400/400
1000
1000
Max 10% less
than 3
More Than
540/540
2000
1350
ER
M
Rail Pressure - BAR
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
MERLIN S3000 COMMON RAIL TEST SYSTEM
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 163
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 16S
Manufacturer I.D.:- PSA 1920 EA
EM
Test Oil Temperature- 40 C
Engine:- PSA RHY/RHS 2.0 HDi
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
mm3st/ccmin
100
300
560/56
500
300
600/300
1000
500
600/600
1000
500
Activate
Aux Button
>400/400
1000
1000
Max 10%
less than 3
More Than
540/540
2000
1350
ER
M
Rail Pressure - BAR
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
MERLIN S3000 COMMON RAIL TEST SYSTEM
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 010 164
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R65/10- 1S
Manufacturer I.D.:- PSA 1920 JE
EM
Test Oil Temperature- 40 C
Engine:- RHY 2.0 HDi
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
350
2000
2000
Rail Pressure - BAR
Conditions
Comments
250
15 Secs
No Unusual noise
500
3 Mins
EL
Bench Speed - RPM
IE
S
Test
1500
No Leaks and
No abnormal
Temperature rise.
2. FUEL DELIVERY
Test
Rail Pressure - BAR
100
300
560/56
500
300
600/300
1000
500
600/600
1000
1000
2000
1350
ER
LI
Bench Speed - RPM
Comments
Delivery
mm3st/ccmin
Max 10%
less than 3
MERLIN S3000 COMMON RAIL TEST SYSTEM
More Than
540/540
600/1200
3. RESISTANCES
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
Test
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 010 168
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L70/20- 8911S
Manufacturer I.D.:-
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
2. Transfer Pressure
LI
Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
Test
Rail Pressure - BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Bench Speed - RPM
Comments
MERLIN S3000 COMMON RAIL TEST SYSTEM
Transfer
Pressure BAR
3. FUEL DELIVERY
100
300
500
300
1000
500
1000
1000
2000
1350
3. RESISTANCES
Comments
Delivery
Mm3st/ccmin
LT
D
Rail Pressure - BAR
500/50
640/320
650/650
Max 10% less
than 3
More Than
580/580
600/1200
Bench Speed - RPM
EM
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
EL
4. SCV Operation
SY
ST
Test
IE
S
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
Bench Speed - RPM
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
1000
NOM
Pump Drv
100%
650/650
NOM
Pump Drv 50%
Nil
Test
1000
ER
LI
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 1.5 BAR
Pump Designation:- 0 445 020 002
Test Oil Specification- ISO 4113
Type Designation:- CR/CP1S3/R70/10- 16S
Manufacturer I.D.:- IVECO 99483254
EM
Test Oil Temperature- 40 C
Engine:- IVECO 8140.43
SY
ST
Direction of Rotation - R
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
1. RUNNING IN/LEAK TEST
Bench Speed - RPM
350
2000
2000
Conditions
250
15 Secs
500
3 Mins
IE
S
Rail Pressure - BAR
EL
Test
1500
Comments
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
Comments
Delivery
Mm3st/ccmin
100
300
500/50
500
300
640/320
1000
500
650/650
1000
500
Activate Aux
Button
>420/420
1000
1000
Max 10% less
than 3
More Than
580/580
2000
1350
ER
M
Rail Pressure - BAR
LI
Bench Speed - RPM
Test
2. FUEL DELIVERY
MERLIN S3000 COMMON RAIL TEST SYSTEM
600/1200
3. RESISTANCES
Test
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
ER
LI
IE
S
EL
SY
ST
EM
LT
D
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 007
Test Oil Specification- ISO 4113
Type Designation:-CR/CP3S3/L110/30-789S
Manufacturer I.D.:- iveco
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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.
Test
Bench Speed - RPM
350
2
3
EL
1. RUNNING IN/LEAK TEST
Conditions
Comments
250
15 Secs
No Unusual noise
2000
500
3 Mins
2000
1500
No Leaks and
No abnormal
Temperature rise.
IE
S
Rail Pressure - BAR
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
970/97
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Delivery
Mm3st/ccmin
Max 10% less
than 3
LT
D
Comments
More Than
950/950
1000/2000
EM
3. RESISTANCES
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
SY
ST
Test
4. SCV Operation
40
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv
50%
Nil
ER
LI
IE
S
Test
EL
Connect lead T031-3002 to fuel pump Suction Control Valve
Set test unit T031-3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 015
Test Oil Specification- ISO 4113
Type Designation:-CR/CP3S3/L110/30-789S
Manufacturer I.D.:- CDC 3954343
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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.
Test
Bench Speed - RPM
350
2
3
EL
1. RUNNING IN/LEAK TEST
Conditions
Comments
250
15 Secs
No Unusual noise
2000
500
3 Mins
2000
1500
No Leaks and
No abnormal
Temperature rise.
IE
S
Rail Pressure - BAR
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
970/97
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Delivery
Mm3st/ccmin
Max 10% less
than 3
LT
D
Comments
More Than
950/950
1000/2000
EM
3. RESISTANCES
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
SY
ST
Test
4. SCV Operation
40
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv
50%
Nil
ER
LI
IE
S
Test
EL
Connect lead T031-3002 to fuel pump Suction Control Valve
Set test unit T031-3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L110/30- 789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- MITSUBISHI ME192242
Pump Designation:- 0 445 020 027
Engine:-
SY
ST
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.
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Comments
Delivery
Cm/1000
LT
D
970/97
Max 10%
less than 3
More Than
950/950
1000/2000
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
SY
ST
EM
3. RESISTANCES
3.2-3.6
40
4. SCV Operation
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv 50%
Nil
ER
LI
IE
S
Test
EL
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
EM
Manufacturer I.D.:- MITSUBISHI ME221816
Pump Designation:- 0 445 020 028
Engine:-
SY
ST
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.
Test
Bench Speed - RPM
350
2
3
EL
1. RUNNING IN/LEAK TEST
Conditions
Comments
250
15 Secs
No Unusual noise
2000
500
3 Mins
2000
1500
No Leaks and
No abnormal
Temperature rise.
IE
S
Rail Pressure - BAR
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Comments
Delivery
Mm3st/ccmin
LT
D
970/97
Max 10% less
than 3
More Than
950/950
1000/2000
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
SY
ST
EM
3. RESISTANCES
4. SCV Operation
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv
Nil
50%
ER
LI
IE
S
Test
EL
Connect lead T031-3002 to fuel pump Suction Control Valve
Set test unit T031-3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 034
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L110/30- 789S
Manufacturer I.D.:- MAN 5111103716
EM
Test Oil Temperature- 40 C
Engine:- D0836
SY
ST
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.
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
970/97
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Max 10% less
than 3
Delivery
Mm3st/ccmin
LT
D
Comments
More Than
950/950
1000/2000
EM
3. RESISTANCES
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
SY
ST
Test
4. SCV Operation
40
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv
Nil
50%
ER
LI
IE
S
Test
EL
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 039
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/R110/30- 789S
Manufacturer I.D.:- 3972815
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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.
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
970/97
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Delivery
Mm3st/ccmin
Max 10% less
than 3
LT
D
Comments
More Than
950/950
1000/2000
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
SY
ST
EM
3. RESISTANCES
3.2-3.6
40
4. SCV Operation
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv 50%
Nil
ER
LI
IE
S
Test
EL
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 045
Test Oil Specification- ISO 4113
Type Designation:-CR/CP3S3/L110/30-789S
Manufacturer I.D.:- CDC 3971529
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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.
Test
Bench Speed - RPM
350
2
3
EL
1. RUNNING IN/LEAK TEST
Conditions
Comments
250
15 Secs
No Unusual noise
2000
500
3 Mins
2000
1500
No Leaks and
No abnormal
Temperature rise.
IE
S
Rail Pressure - BAR
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Comments
Delivery
Mm3st/ccmin
Max 10% less
than 3
LT
D
970/97
More Than
950/950
1000/2000
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
3.2-3.6
40
SY
ST
EM
3. RESISTANCES
4. SCV Operation
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv 50%
Nil
ER
LI
IE
S
Test
EL
Connect lead T031-3002 to fuel pump Suction Control Valve
Set test unit T031-3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail
Test System
LT
D
TEST DATA
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Pump Designation:- 0 445 020 054
Test Oil Specification- ISO 4113
Type Designation:- CR/CP3S3/L110/30- 789S
Manufacturer I.D.:- SISU 837069146
EM
Test Oil Temperature- 40 C
Engine:-
SY
ST
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.
Test
Bench Speed - RPM
EL
1. RUNNING IN/LEAK TEST
Rail Pressure - BAR
Conditions
350
250
15 Secs
2000
500
3 Mins
2000
1500
No Unusual noise
No Leaks and
No abnormal
Temperature rise.
IE
S
Comments
Bench Speed - RPM
LI
Test
2. Transfer Pressure
Comments
Transfer
Pressure BAR
350
250
1.5-2.0
1000
500
4.0-5.0
2000
1350
2.5-3.0
ER
Rail Pressure - BAR
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. FUEL DELIVERY
Test
Bench Speed - RPM
Rail Pressure - BAR
100
300
500
300
1100/550
1000
500
1100/1100
1000
1000
2000
1350
Comments
Delivery
Mm3st/ccmin
LT
D
970/97
Max 10% less
than 3
More Than
950/950
1000/2000
Test
Bench Speed - RPM
SCV Resistance
Temp Sender
Resistance
INLET FUEL
TEMP C
2.8-3.2
20
SY
ST
EM
3. RESISTANCES
3.2-3.6
40
4. SCV Operation
Bench Speed - RPM
1000
1000
Rail Pressure - BAR
Comments
Delivery
Mm3st/ccmin
NOM
Pump Drv
100%
1100/1100
NOM
Pump Drv
50%
Nil
ER
LI
IE
S
Test
EL
Connect lead T031- 3002 to fuel pump Suction Control Valve
Set test unit T031- 3000 to SCV.
MERLIN S3000 COMMON RAIL TEST SYSTEM
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