S3000 Common Rail

Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

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

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 92-98 <60.0 <90.0 Max Fuel
1500 1200 1200 62-68 High Mid Range
1500 800 600 32-39 Mid Range
1500 400 600 17-23 Light Load
400 250 700 11-15 Idle
400 150-250 700 N/A S.O.I
400 800 100 0.5-4.0 Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40000Z TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: PSA 9636680280 1980.F0 TEST OIL TEMP: 40C
ENGINE: DW10 BTED 2.0HDi 64kW CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 77-82 <60.0 <90.0 Max Fuel

1500 1200 1200 60-63 High Mid Range

1500 800 600 25-30 Mid Range

1500 400 600 18-22 Light Load

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

400 800 80 1.0-3.0 Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40057 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511315 TEST OIL: ISO 4113
O.E.M. REF: FORD 4S7Q 9K546 AF TEST OIL TEMP: 40C
ENGINE: JAGUAR 2.7V6 CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 85-88 <60.0 <90.0 Max Fuel

1500 1200 1200 58-61 High Mid Range

1500 800 600 27-30 Mid Range

1500 400 600 18-20 Light Load

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

400 800 100 - Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40086 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511610 TEST OIL: ISO 4113
O.E.M. REF: FORD TEST OIL TEMP: 40C
CAPACITANCE: 3.0-4.5 Uf @ 20C
ENGINE: -

Remove all washers from injectors.

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

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

Pump Rail Max Back Leak

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

1000 1150 1200 57-63 - - Max Torque

1000 1000 700 30-36 - - Emissions

1000 850 120 0.5-2.5 - - Pre-Injection

400 250 500 4-8 - - Idle

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40087 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511606 TEST OIL: ISO 4113
O.E.M. REF: REN K9KIAM VERS TEST OIL TEMP: 40C
ENGINE: K9K CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 55-60 <60.0 <90.0 Max Fuel

1500 1200 1200 N/A High Mid Range

1500 800 600 N/A Mid Range

1500 400 600 N/A Light Load

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

400 800 100 - Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40103 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511316 TEST OIL: ISO 4113
O.E.M. REF: FORD 5U3Q 9K546 AA TEST OIL TEMP: 40C
ENGINE: LION V6 EURO 4 JAGUAR & PSA CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 85-88 <60.0 <90.0 Max Fuel

1500 1200 1200 58-62 High Mid Range

1500 800 600 27-30 Mid Range

1500 400 600 16-18 Light Load

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

400 800 100 -- Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40148Z (5WS-40007) TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: FORD 2S6Q9F593AB TEST OIL TEMP: 40C
PSA 1980.E7 CAPACITANCE: 3.0-4.5 Uf @ 20C
ENGINE: DV41.4HDi 50Kw EURO 3

Remove all washers from injectors.

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

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

Pump Rail Max Back Leak

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

1000 1150 1200 44-50 - - Max Torque

1000 1000 700 23-29 - - Emissions

1000 850 120 0.5-2.5 - - Pre-Injection

400 250 500 3-7 - - Idle

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40149-Z TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511612 TEST OIL: ISO 4113
O.E.M. REF: FORD, PSA EURO 4 TEST OIL TEMP: 40C
ENGINE: 1.4 L CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail Max Back Leak

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

1000 1150 1200 36-41 - - Max Torque

1000 1000 700 24-29 - - Emissions

1000 850 100 0.5-2.0 - - Pre-Injection

400 250 600 5-8 - - Idle

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40156-4Z TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: FORD FOCUS 1.8 EURO 4 TEST OIL TEMP: 40C
ENGINE: - CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 82-86 <60.0 <90.0 Max Fuel

1500 1200 1200 57-63 High Mid Range

1500 800 600 26-30 Mid Range

1500 400 600 15-20 Light Load

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

400 800 100 - Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40156Z TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF:FORD 1373550 TEST OIL TEMP: 40C
PSA 9659244280
CAPACITANCE: 3.0-4.5 Uf @ 20C
VOLVO 8603564
ENGINE: DW10 2.0HDI 100KW (CLASS 5)

Remove all washers from injectors.

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

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

Pump Rail Max Back Leak

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

1000 1150 1200 55-61 - - Max Torque

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

400 250 500 5-8 - - Idle

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40200 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511602 TEST OIL: ISO 4113
O.E.M. REF: PSA 1980K5 TEST OIL TEMP: 40C
ENGINE: PSA DW10 2.0 HDi 100KW CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 88-92 <60.0 <90.0 Max Fuel

1500 1200 1200 60-63 High Mid Range

1500 800 600 30-34 Mid Range

1500 400 600 12-14 Light Load

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

400 800 100 - Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40249 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511364 TEST OIL: ISO 4113
O.E.M. REF: LAND ROVER LR006495 TEST OIL TEMP: 40C
ENGINE: DT17 2.7 V6 CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 76-81 <60.0 <90.0 Max Fuel

1500 1200 1200 52-57 High Mid Range

1500 800 600 27-30 Mid Range

1500 400 600 15-17 Light Load

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

400 800 100 0.5-2.0 Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40250 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511611 TEST OIL: ISO 4113
O.E.M. REF: FORD 1432322 TEST OIL TEMP: 40C
ENGINE: LYNX 1.8 TDCI 85-92KW CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail Max Back Leak

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

1000 1150 1200 37-43 - - Max Torque

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

400 250 500 3-7 - - Idle

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40252 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59513553 TEST OIL: ISO 4113
O.E.M. REF: LANDROVER TEST OIL TEMP: 40C
ENGINE: LION V6 UG CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 75-80 <60.0 <90.0 Max Fuel

1500 1200 1200 N/A High Mid Range

1500 800 600 N/A Mid Range

1500 400 600 N/A Light Load

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

400 800 100 - Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40253 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: 6H4Q-9K-546CB TEST OIL TEMP: 40C
ENGINE: FORD/ PSA LION V6 CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1200 65-70 <60.0 <90.0 Max Fuel

1500 1200 900 45-50 High Mid Range

1500 800 600 29-31 Mid Range

1500 400 400 8-9 Light Load

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

400 800 100 - Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40387 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59513597 TEST OIL: ISO 4113
O.E.M. REF: 6H4Q-9K-546CB TEST OIL TEMP: 40C
ENGINE: FORD/ PSA LION V6 CAPACITANCE: 3.0-4.5 Uf @ 20C
R/ROVER SPORT 3.6L V8

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1200 65-70 <60.0 <90.0 Max Fuel
1500 1200 900 45-50 High Mid Range
1500 800 600 29-31 Mid Range
1500 400 400 8-9 Light Load
400 250 700 10-11 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40441 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511603 TEST OIL: ISO 4113
O.E.M. REF: PSA 1980K8 TEST OIL TEMP: 40C
ENGINE: PSA DW10 2.0 HDi 100KW CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 77-80 <60.0 <90.0 Max Fuel

1500 1200 1200 55-58 High Mid Range

1500 800 600 27-30 Mid Range

1500 400 600 12-14 Light Load

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

400 800 100 - Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40516 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59511612 TEST OIL: ISO 4113
O.E.M. REF: PSA 9663429280 TEST OIL TEMP: 40C
ENGINE: DV4 TD CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 87-93 <60.0 <90.0 Max Fuel

1500 1200 1200 57-63 High Mid Range

1500 800 600 27-32 Mid Range

1500 400 600 14-18 Light Load

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

400 800 100 0.5-4 Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40539 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59513554 TEST OIL: ISO 4113
O.E.M. REF: VW/AUDI/SKODA TEST OIL TEMP: 40C
ENGINE: 1.6L CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1200 62-68 <60.0 <90.0 Max Fuel

1500 1200 900 47-53 High Mid Range

1500 800 600 27-33 Mid Range

1500 400 440 10-14 Light Load

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

400 800 100 - Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 5WS-40677 TEST PUMP: SUITABLE CR PUMP
TYPE: A2C59513556 TEST OIL: ISO 4113
O.E.M. REF: PSA/ FORD/MAZDA/VOLVO TEST OIL TEMP: 40C
ENGINE: 1.5L (82kW) CAPACITANCE: 3.0-4.5 Uf @ 20C

Remove all washers from injectors.

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

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

Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System & Check
1000 1000 700 N/A
- - for Leaks
1500 1600 1600 77-82 <60.0 <90.0 Max Fuel

1500 1200 1200 60-63 High Mid Range

1500 800 600 32-36 Mid Range

1500 400 600 22-24 Light Load

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

Pre Injection

Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail
pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure
should be 150-200BAR.

Dry Seat Test

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

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

MERLIN S3000 COMMON RAIL TEST SYSTEM