MERLIN DIESEL SYSTEMS LTD

189-191, Bradkirk Place, Walton Summit Centre

Preston, Lancashire, PR5 8AJ, England
Tel: +44 (0)1772 694180 Fax: +44 (0)1772 314565
E: sales@merlindiesel.com W: www.merlindiesel.com
Manufacturers part numbers are given for reference purposes only and do not imply that in all cases the parts are of their manufacture.
Illustrations and Technical Data are non-binding and are subject to change as a result of technological progress. DATA REF: MDS-TE 0140-0112
Pumps Parts Test Equipment Filters New Generation Workshops Diagnostic & Vehicle Care Centre
FOR MORE INFORMATION PLEASE CALL 01772 694180
T016- 852
Digital External Micrometer
Range: 0-25mm Resolution: 0.001mm
T016- 848
40x Magnifier
T021- 958
Vacuum pen for steel ball
T021- 959
Insulation Tester for pre-checking
T016- 851
Tweezers for steel ball
New Common Rail Tools & Accessories
MERLIN S350K
New Merlin kit for stage 3 repair
(pilot valve replacement) on all
Bosch common rail injectors
including:-
CRI 2.1 AND CRIN 1, 2 & 3
Consists of:-
T021- 956
Dial gauge holder kit
For measuring ball bearing stroke on all
Bosch common rail injectors.
Supplied with 17 & 19mm adaptors
S350
Armature stroke test unit c/w 3 adaptor
cables
T016- 850
Digital dial indicator 12.5/0.001mm
Range: 12.500 mm
Resolution: 0.001 mm
T021- 957
Pin for T016-850 & T021-956
All parts are available separately
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.
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Injector Designation:- 0 445 110 002
Type Designation:- CR/IPS19/ZEREK10S
Manufacturer I.D.:- FIAT 46472233
Engine:- 182 B 4000 1.9 JTD
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
50-55
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 012
Type Designation:- CR/IPS19/ZERAK10S
Manufacturer I.D.:- DB 611 070 05 87
Engine:- OM611-961/980
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
73-77
<35.0/55.0 Max Fuel
400 250 700
14.0-15.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 015
0 986 435 005
Type Designation:- CR/IPS19/ZEREAK20S
Manufacturer I.D.:- DB 668 070 02 87
Engine:- OM668-941
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
52-57
<35.0/55.0 Max Fuel
400 250 700
11.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 019
Type Designation:- CR/IPS19/ZERAK10S
Manufacturer I.D.:- FIAT 46547897
Engine:- 188 A 2.000 1.9JTD
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Commen
ts
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
60-65
<35.0/55.0 Max Fuel
400 250 700
12.0-13.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 021
0 986 435 007
Type Designation:- CR/IPS19/ZEREK10S
Manufacturer I.D.:- RENAULT 7700 107 165
Engine:- F9Q 1.9DCi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
64-69
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 025
0 986 435 020
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- DB 611 070 06 87
Engine:- OM611-961 611-981
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
65-70
<35.0/55.0 Max Fuel
400 250 700
13.0-14.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 029
Type Designation:- CR/IFS17/ZERAK10S
Manufacturer I.D.:- BMW 13 53 7 785 437
Engine:- 30 6 D1 3.0D
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
61-66
<35.0/55.0 Max Fuel
400 250 700
5.0-7.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 030
0 986 435 011
Type Designation:- CR/IFS17/ZERAK10S
Manufacturer I.D.:- BMW 13 53 2 354 045
Engine:- 30 4 D1 2.0D
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
55-60
<35.0/55.0 Max Fuel
400 250 700
8.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 035
0 986 435 012
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- DB 613 070 01 87
Engine:- OM611.981 OM611.987
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
71-76
<35.0/55.0 Max Fuel
400 250 700
12.0-13.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 036
Type Designation:- CR/IFS17/ZEREW10S
Manufacturer I.D.:- PSA 96533448
Engine:- PSA2.2HDi 4HX
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
62-66
<35.0/55.0 Max Fuel
400 250 700
11.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 76-78 <35.0 <55.0 Max Fuel
400 250 700 8-9 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
400 400 60 0.2-3.0 - - Pre Injection
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 038 (0 986 435 016)
TYPE: CR/IFS17/ZEREK10S
O.E.M. REF: RENAULT 8200 010 074
ENGINE: G9T-710
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 044
0 986 435 003
Type Designation:- CR/IPS17/ZEREK10S
Manufacturer I.D.:- PSA 96375360/1980-72
Engine:- 2.0 HDi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
57-60
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 047
Type Designation:- CR/IFS17/ZEREK10S
Manufacturer I.D.:- BMW 13 53 778 984
Engine:- 30 6 D1
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
70-72
<35.0/55.0 Max Fuel
400 250 700
8.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 048
Type Designation:- CR/IFS17/ERAK10S
Manufacturer I.D.:- BMW 13 53 7 785 574
Engine:- 25 6D1
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
55-60
<35.0/55.0 Max Fuel
400 250 700
7.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 049
Type Designation:- CR/IFS17/ZERAK10S
Manufacturer I.D.:- BMW 1353 7 785 983
Engine:-
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Comments
1000 1000 1200 Purge System
2000 1500 1200 N/A Check for Leaks
1500 1350 900 53.0-57.0 Max Fuel
400 250 700 6.0-8.0 Idle
1500 1350 900 <35 Max Back leakage
2000 1350 Run pump only <12.5 Max Back leakage
400 150-200 700 - S.O.I
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Injector Designation:- 0 445 110 054
Type Designation:- CR/IPL19/ZERAK20S
Manufacturer I.D.:- DB 611 070 11 87
Engine:- OM646-951/961
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
73-77
<35.0/55.0 Max Fuel
400 250 700
14.0-15.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 057
Type Designation:- CR/IPS17/ZERAK10S
Manufacturer I.D.:- PSA 1980-78
Engine:- RHW 2.0HDi 16v
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
55-60
<35.0/55.0 Max Fuel
400 250 700
11.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 059
Type Designation:- CR/IPL19/ZERAK10S
Manufacturer I.D.:- VM 1506 2036F
Engine:- 2.5CRD
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T016-3052 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
80-83
<35.0/55.0 Max Fuel
400 250 700
11.5-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 062
0 986 435 077
Type Designation:- CR/IPS17/ZEREK10S
Manufacturer I.D.:- PSA 96400887
Engine:- PSA 2.0HDi RHY
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
60-64
<35.0/55.0 Max Fuel
400 250 700
13.0-14.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 063
Type Designation:- CR/IPS17/ZERAK10S
Manufacturer I.D.:- RENAULT 8200010075
Engine:- 1.9 DCi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Comments
1000 1000 1200 Purge System
2000 1500 1200 N/A Check for Leaks
1500 1350 900 55-60 Max Fuel
400 250 700 10.0-12.0 Idle
1500 1350 900 <35 Max Back leakage
2000 1350 Run pump only <12.5 Max Back leakage
400 150-200 700 0.01-0.1 S.O.I
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Injector Designation:- 0 445 110 064
0 445 110 101
Type Designation:- CR/IPL17/ZERAK10S
Manufacturer I.D.:- HYUNDAI 33800-27000
Engine:- D3EA/D4EA
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
65-68
<35.0/55.0 Max Fuel
400 250 700
10.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 068
Type Designation:- CR/IPS19/ZERAK10S
Manufacturer I.D.:- FIAT 46787376
Engine:- 182 B 9.000/ 186 A 6.000 1.9JTD
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
77-80
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 069
Type Designation:- CR/IPS19/ZERAK10S
Manufacturer I.D.:- DB 611 070 08 87
Engine:- OM611-981/OM611-987
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
72-75
<35.0/55.0 Max Fuel
400 250 700
14.0-15.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 069
0 445 110 070
Type Designation:- CR/IPS19/ZERAK10S
Manufacturer I.D.:- 611 070 08 07
Engine:- OM611.981 / 987
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
72-75
<35.0/55.0 Max Fuel
400 250 700
14.0-15.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 072
0 986 435 071
Type Designation:- CR/IPS19/ZEREAK20S
Manufacturer I.D.:- DB 611 070 09 87
Engine:- OM611-962
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
64-68
<35.0/55.0 Max Fuel
400 250 700
12.0-13.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 075
0 986 435 076
Type Designation:- CR/IPL20/ZEREAK20S
Manufacturer I.D.:- PSA 96386523
Engine:- 8HX / 8HZ
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
43-47
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 076
0 986 435 077
Type Designation:- CR/IPS17/ZEREK10S
Manufacturer I.D.:- PSA 96533448
Engine:- PSA2.0HDi RHS/RHY
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
60-64
<35.0/55.0 Max Fuel
400 250 700
13.0-14.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 078
Type Designation:- CR/IFS19/ZERAK20S
Manufacturer I.D.:- VOLVO 8658350
Engine:- D5244T
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
69-71
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 080
0 986 435 084
Type Designation:- CR/IFL17/ZEREAK20S
Manufacturer I.D.:- BMW 13 53 7 787 234
Engine:- 20 4 D4 / 30 6 D2
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
80-84
<35.0/55.0 Max Fuel
400 250 700
14.5-15.5
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 081
Type Designation:-
Manufacturer I.D.:-
Engine:-
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
84.0-87.0
<35.0/55.0 Max Fuel
400 250 700
8.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 083
Type Designation:- CR/IPL17/ZERAK10S
Manufacturer I.D.:- FIAT 55184536
Engine:- 1.3JTD /OPEL 1.3CDTI
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
65-70
<35.0/55.0 Max Fuel
400 250 700
8.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 084
Type Designation:- CR/IFL19/ZERAK10S
Manufacturer I.D.:- RENAULT 8200084534
Engine:- REN 2.2 DCi 110KW G9T-742
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
68-73
<35.0/55.0 Max Fuel
400 250 700
11.5-12.5
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 087
Type Designation:- CR/IFS19/ZERAK10S
Manufacturer I.D.:- RENAULT 8200101135
Engine:- REN 1.9 DCi OPEL 1.9 DTi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
77-80
<35.0/55.0 Max Fuel
400 250 700
11.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 090
0 986 435 033
Type Designation:- CR/IPL19/ZEREAK10S
Manufacturer I.D.:- DB 668 070 08 87
Engine:- OM668-914
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
56-60
<35.0/55.0 Max Fuel
400 250 700
14.0-15.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 091
Type Designation:- CR/IPL19/ZERAK10S
Manufacturer I.D.:- HYUNDAI 33800-4A000
Engine:- D4CB 2.5CRDI
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
78-84
<35.0/55.0 Max Fuel
400 250 700
5.5-7.5
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 093
0 986 435 035
Type Designation:- CR/IPL19/ZEREAK10S
Manufacturer I.D.:- DB 611 070 03 87
Engine:- OM628-962
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
67-71
<35.0/55.0 Max Fuel
400 250 700
11.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 095
0 986 435 037
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- DB 613 070 05 87
Engine:- OM611-981 / OM611-987
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
75-78
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 096
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- OM612.965
Engine:- MB
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
70-75
<35.0/55.0 Max Fuel
400 250 700
10.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 098
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- OM612.965
Engine:- MB
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
70-75
<35.0/55.0 Max Fuel
400 250 700
10.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 100
0 986 435 041
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- DB 611 070 13 87
Engine:- OM611-962
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
67-72
<35.0/55.0 Max Fuel
400 250 700
11.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 101
Type Designation:- CR/IPL17/ERAK10S
Manufacturer I.D.:- HYUNDAI 33800-27000
Engine:- D3EA/D4EA
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
67-72
<35.0/55.0 Max Fuel
400 250 700
10.5-11.5
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 102
Type Designation:- CR/IFS19/ERAK10S
Manufacturer I.D.:- RENAULT 8200 112 289
Engine:- G9T-722 / G9T-750 2.2DCi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
57-62
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 106
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- DB 611 070 14 87
Engine:- OM611-981 OM644-987
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
73-77
<35.0/55.0 Max Fuel
400 250 700
13.0-14.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 108
0 986 435 047
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- DB 611 070 16 87
Engine:- OM611-981 OM644-987
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
73-77
<35.0/55.0 Max Fuel
400 250 700
13.0-14.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 110
0 986 435 080
Type Designation:- CR/IPS19/ZEREK10S
Manufacturer I.D.:- RENAULT 8200 100 272
Engine:- 1.9 DCi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
64-67
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 111
Type Designation:- CR/IPL17/ZERAK10S
Manufacturer I.D.:- Fiat 55192534
Engine:- 192 B / 537 A
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
85-90
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 112
Type Designation:- CR/IPS19/ZERAK10S
Manufacturer I.D.:- FIAT 55184535
Engine:- 1.9JTD 8V
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
85-90
<35.0/55.0 Max Fuel
400 250 700
8.5-9.5
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 113
Type Designation:- CR/IFS19/ZERAK10S
Manufacturer I.D.:- VW 057130276H
Engine:- AKF3.3TDi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
62-67
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
M
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Injector Designation:- 0 445 110 116
0 986 435 049
Type Designation:- CR/IPL19/ZEREAK10S
Manufacturer I.D.:- DB 668 070 09 87
Engine:- OM668-940
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
56-60
<35.0/55.0 Max Fuel
400 250 700
10.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 118
Type Designation:- CR/IPL17/ERAK20S
Manufacturer I.D.:- OPEL 97300091
Engine:- Z17DTL
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
50-55
<35.0/55.0 Max Fuel
400 250 700
15.0-16.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 119
Type Designation:- CR/IPS19/ZERAK10S
Manufacturer I.D.:- FIAT 55187290
Engine:- 1.9JTD 8V
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
80-85
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 121
0 986 435 051
Type Designation:- CR/IPL19/ZEREAK10S
Manufacturer I.D.:- DB 613 070 03 87
Engine:- OM611-962 / OM612-962
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
70-72
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 125
Type Designation:- CR/IFL19/ZEREAK10S
Manufacturer I.D.:- MWM 94 070 46 4 0024
Engine:-
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
80-85
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 130
Type Designation:- CR/IFS17/ZEREK10S
Manufacturer I.D.:- BMW 13 53 7 789 573
Engine:-
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
52.5-57.5
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 105-115 <35.0 55.0 Max Fuel
400 250 700 6-10 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 131
TYPE: CR/IPS17/ZEREK10S
EXCHANGE: -
O.E.M. REF: BMW 13 53 7 787 234
ENGINE: 30 6 D2 3.0d 110/150/160 KW
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 135
0 986 435 085
Type Designation:- CR/IPS19/ZEREK20S
Manufacturer I.D.:- PSA 96487862
Engine:- 1.4HDi 8HX/8HZ
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
41-45
<35.0/55.0 Max Fuel
400 250 700
11.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 136
Type Designation:- CR/IFL17/ZEREK20S
Manufacturer I.D.:- FORD 3M5Q 9F593 CA
Engine:- 1.6 TDCI
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
47-50
<35.0/55.0 Max Fuel
400 250 700
5.0-6.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 139/140
Type Designation:- CR/IPS19/ZEREAK20S
Manufacturer I.D.:- DB 646 070 02 87
Engine:- OM646-982
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
81-86
<35.0/55.0 Max Fuel
400 250 700
11.5-12.5
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 141
Type Designation:- CR/IPS19/ZERAK10S
Manufacturer I.D.:- RENAULT 8200146357
Engine:- G9U-724 / G9U-754 2.5DCi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
92-95
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 146
0 986 435 087
Type Designation:- CR/IPS19/ZEREK10S
Manufacturer I.D.:- RENAULT 8200 238 528
Engine:- F9Q 820
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
64-69
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 149
Type Designation:- CR/IFL17/ZEREAK20S
Manufacturer I.D.:- BMW 13 53 7 790 630
Engine:- 20 4 D 4 1.8D
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
55-60
<35.0/55.0 Max Fuel
400 250 700
5.0-7.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 70-75 <35.0 <55.0 Max Fuel
400 250 700 8-10 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 156 (155)
TYPE: CR/IPS19/ZERES20S
O.E.M. REF: MERCEDES BENZ
ENGINE: OM646.951/961 + VARIOUS
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 158
Type Designation:- CR/IFL19/ZEREAK20S
Manufacturer I.D.:- VW 057 130 277 L
Engine:- ASE 4.0 TDI
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
75.0-80.0
<35.0/55.0 Max Fuel
400 250 700
8.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 159
Type Designation:- CR/IPL17/ZEREAK20S
Manufacturer I.D.:- OPEL 55192739
Engine:- Z19 DTH
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
95-99
<35.0/55.0 Max Fuel
400 250 700
8.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 97-103 <35.0 55.0 Max Fuel
400 250 700 4-7 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 161
TYPE: CR/IFL17/ZEREA20S
EXCHANGE: 0 986 435 091
O.E.M. REF: BMW
ENGINE: 204D4, 306D2
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 165
Type Designation:- CR/IPL19/ZEREK20S
Manufacturer I.D.:- VAUXHALL/OPEL
Engine:- 1.9 CDTI
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors.
Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Comments
1000 1000 1200 Purge System
2000 1500 1200 N/A Check for Leaks
1500 1350 900 80-85 Max Fuel
400 250 700 3.0-6.0 Idle
1500 1350 900 <35 Max Back leakage
2000 1350 Run pump only <12.5 Max Back leakage
400 150-200 700 0.01-0.1 S.O.I
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Injector Designation:- 0 445 110 168
Type Designation:- CR/IPL17/ZEREK20S
Manufacturer I.D.:- NISSAN 16600 DB 000
Engine:- 1.6 HDi -
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
95-100
<35.0/55.0 Max Fuel
400 250 700
6.0-7.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 112-118 <35.0 55.0 Max Fuel
400 250 700 6-9 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 169
TYPE: CR/IPL17/ZEREK20S
EXCHANGE: -
O.E.M. REF: RENAULT 3.0L
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 54-60 <35.0 <55.0 Max Fuel
400 250 700 9-11 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 174
TYPE: CR/IPL21/ZERES20S
O.E.M. REF: OPEL
ENGINE: 1.7 CDTi
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 175
Type Designation:- CR/IPl17/ZEREK20S
Manufacturer I.D.:- OPEL 897 363 812
Engine:- OM648
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
1500 1350 900
58-64
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 177
Type Designation:- CR/IPS19/ZEREAK20S
Manufacturer I.D.:- DB 648 070 02 87
Engine:- OM648
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
64-70
<35.0/55.0 Max Fuel
400 250 700
10.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 64-68 <35.0 <55.0 Max Fuel
400 250 700 10-12 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 181
TYPE: CR/IPS19/ZEREAK10S
O.E.M. REF: MERCEDES SPRINTER/VITO
ENGINE: 2.2/2.7L
Injector Designation:- 0 445 110 183
Type Designation:- CR/IPL17/ZEREK20S
Manufacturer I.D.:- OPEL 93184178
Engine:- Z13 DTH
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
68-72
<35.0/55.0 Max Fuel
400 250 700
7.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 186/279
Type Designation:- CR/IPL19/ZEREK10S
Manufacturer I.D.:- HYUNDAI 33800 4A100
Engine:- D4CB 2.5Lt
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
88.0-93.0
<35.0/55.0 Max Fuel
400 250 700
8.0-10-0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 187
Type Designation:- CR/IPL17/ZEREK20S
Manufacturer I.D.:- FIAT 55197875
Engine:- 1.3JTD 8V
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
70-75
<35.0/55.0 Max Fuel
400 250 700
11.0-12.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 188
Type Designation:- CR/IFS17/ZERAK20S
Manufacturer I.D.:- PSA 1980-H3
Engine:- 1.6 HDi - FORD 1.6 TDCi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
52-55
<35.0/55.0 Max Fuel
400 250 700
8.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 190
0 986 435 045
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- DB 611 070 16 87
Engine:- OM611-981 OM644-987
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
73-77
<35.0/55.0 Max Fuel
400 250 700
13.0-14.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 192
0 445 110 191
Type Designation:- CR/IPS19/ZEREAK20S
Manufacturer I.D.:- 647 070 00 87
Engine:- OM646.982
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
73-76
<35.0/55.0 Max Fuel
400 250 700
12.0-13.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 68-72 <35.0 55.0 Max Fuel
400 250 700 8-10 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 201 / 202
TYPE: CR/IPS19/ZEREAK10S
O.E.M. REF: MERCEDES BENZ
ENGINE: 2.2L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 206
Type Designation:- CR/IPS19/ZEREAK10S
Manufacturer I.D.:- DB 613 070 09 87
Engine:-
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
68-74
<35.0/55.0 Max Fuel
400 250 700
8.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 108-113 <35.0 55.0 Max Fuel
400 250 700 5-8 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 213
TYPE: CR/IPL17/ZERAK20S
EXCHANGE: -
O.E.M. REF: FIAT 55192740
ENGINE: 939 A 3000 2.4JTD 20V
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 44-48 <35.0 55.0 Max Fuel
400 250 700 4-6 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 215
TYPE: CR/IPS17/ZEREK20S
EXCHANGE: -
O.E.M. REF: 23670-33030
ENGINE: TOYOTA
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 216
Type Designation:- CR/IFL17/ZEREAK20S
Manufacturer I.D.:- BMW 13 53 7793836
Engine:- 30 6 D2 / 20 4 D4
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
100-105
<35.0/55.0 Max Fuel
400 250 700
8.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 72-77 <35.0 55.0 Max Fuel
400 250 700 6-9 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 230
TYPE: CR/IPL19/ZEREK20S
O.E.M. REF: RENAULT/SUZUKI
ENGINE: 1.9L, F9Q
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 237/238
Type Designation:- CR/IPl19/ZERAK20S
Manufacturer I.D.:- DB 646 070 07 87
Engine:- OM646-966
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back
Leak
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
50-55
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 239
Type Designation:- CR/IFL17/ZEREK20S
Manufacturer I.D.:- PSA 1980 H2
Engine:- 9HX 1.6 HDi
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
47-50
<35.0/55.0 Max Fuel
400 250 700
9.0-1.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 243
Type Designation:- CR/IPL17/ZEREK20S
Manufacturer I.D.:- FIAT/OPEL 55198218
Engine:- 1.9 CDTI 150 HP
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
95-100
<35.0/55.0 Max Fuel
400 250 700
7.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 102-108 <35.0 <55.0 Max Fuel
400 250 700 5-7 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
400 400 60 0.2-3.0 - - Pre Injection
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 248
TYPE: CR/IPL21/ZERES20S
O.E.M. REF: IVECO 504088823
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 77-82 <35.0 <55.0 Max Fuel
400 250 700 8-10 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
- - - - - - Pre Injection
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 251
TYPE: CR/IPL21/ZEREZ20S
O.E.M. REF: IVECO 504088823
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 98-102 <35.0 <55.0 Max Fuel
400 250 700 8-11 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 258
TYPE: CR/IPL19/ZEREK20S
O.E.M. REF: HYUNDAI / KIA
ENGINE: 2.0L
Injector Designation:- 0 445 110 259
Type Designation:- CR/IFL17/ZEREK20S
Manufacturer I.D.:- FIAT 46472233
Engine:- 182 B 4000 1.9 JTD
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
50-55
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 265
Type Designation:- CR/IPL19/ZEREAK20S
Manufacturer I.D.:- NISSAN
Engine:- 2.5
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
95-100
<35.0/55.0 Max Fuel
400 250 700
10.5-12.5
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 266
Type Designation:- CR/IFS17/ZERAK10S
Manufacturer I.D.:- BMW 13 53 7785 94
Engine:- 30 6 D1
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
69-72
<35.0/55.0 Max Fuel
400 250 700
8.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 273
Type Designation:- CR/IPL19/ZEREK20S
Manufacturer I.D.:-IVECO 5040887755
Engine:- FIAE 0481F Daily 2.3
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
83-90
<35.0/55.0 Max Fuel
400 250 700
6.0-7.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 108-112 <35.0 <55.0 Max Fuel
400 250 700 8-10 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 275
TYPE: CR/IPL19/ZEREK20S
O.E.M. REF: HYUNDAI/KIA
ENGINE: 2.5L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 276
Type Designation:- CR/IPL17/ZERAK20S
Manufacturer I.D.:- FIAT 55200259
Engine:- 939.A.7000 1.9JTD
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
90-95
<35.0/55.0 Max Fuel
400 250 700
10.0-11.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 279
Type Designation:- CR/IPL19/ZEREK10S
Manufacturer I.D.:- HYUNDAI 33800 4A100
Engine:- D4CB 2.5Lt
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
62-67
<35.0/55.0 Max Fuel
400 250 700
5.0-7.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 280
Type Designation:- CR/IPL19/ZEREK20S
Manufacturer I.D.:- RENAULT 8200606383
Engine:-
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
100-110
<35.0/55.0 Max Fuel
400 250 700
9.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 76-80 <35.0 55.0 Max Fuel
400 250 700 9-11 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 286
TYPE: CR/IPL17/ZEREK20S
EXCHANGE: -
O.E.M. REF: -
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 69-75 <35.0 <55.0 Max Fuel
400 250 700 5-8 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 290 (WAS 126)
TYPE: CR/IPL17/ZEREK10S
O.E.M. REF: HYUNDAI / KIA
ENGINE: 2.0 CRDi
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 296
Type Designation:- CR/IPL19/ZEREK20S
Manufacturer I.D.:-RENAULT 8200606383
Engine:-
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
58-62
<35.0/55.0 Max Fuel
400 250 700
8.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3201.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 68-72 <35.0 55.0 Max Fuel
400 250 700 6-8 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 297
TYPE: CR/IFL17/ZEREK20S
EXCHANGE: 0 986 435 150
O.E.M. REF: PEUGEOT/CITROEN
ENGINE: 1.6 HDi
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 110 308
Type Designation:- CR/IPL17/ZEREK20S
Manufacturer I.D.:- FIAT 53208183
Engine:- 939 A 9000 2.4 JTD 20v
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
105-110
<35.0/55.0 Max Fuel
400 250 700
8.0-10.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 110 311
Type Designation:-
Manufacturer I.D.:-
Engine:-
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3003 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
73.0-77.0
<35.0/55.0 Max Fuel
400 250 700
8.0-9.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 117-122 <35.0 <55.0 Max Fuel
400 250 700 6-8 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 327
TYPE: CR/IPL17/ZEREK20S
O.E.M. REF: VAUXHALL/OPEL
ENGINE: 2.0L
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 105-110 <35.0 <55.0 Max Fuel
400 250 700 4-7 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
400 400 60 0.2-3.5 - - Pre Injection
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 338
TYPE: CRI 2.2
O.E.M. REF: RENAULT
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 104-109 <35.0 <55.0 Max Fuel
400 250 700 6-8 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
400 400 60 0.2-4.0 - - Pre Injection
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 375
TYPE: -
O.E.M. REF: -
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
M
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Y
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A - -
Purge System & Check for
Leaks
1500 1350 900 78-83 <35.0 <55.0 Max Fuel
400 250 700 10-12 <20.0 <9.0 Idle
2000 1350
Run pump
only
N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
400 400 40 0.2-4.0 - - Pre Injection
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 110 414
TYPE: CRI 2.5
O.E.M. REF: -
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
M
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables.(T031-3003R)
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System &
Check for Leaks
1000 1450 1200 105-115 <40.0 60.0 Max Fuel
1000 1450 900 72-82 Mid Range
1000 1450 700 52-62 - - Low Speed
1000 500 700 20-25 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
INJECTOR DATA
PART No: 0 445 115 007
TYPE: CR/IPS19/ZEREAK50S
O.E.M. REF: -
ENGINE: M9R
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
CAPACITANCE: 2.1-3.1 Uf @ 20C
S3000 Common Rail
Test System
TEST DATA
M
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System &
Check for Leaks
1000 1450 1200 107-117 <40.0 60.0 Max Fuel
1000 1450 900 75-84 Mid Range
1000 1450 700 54-60 - - Low Speed
1000 500 700 20-25 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
INJECTOR DATA
PART No: 0 445 115 025
TYPE: CR/IPL19/ZEREAK50S
O.E.M. REF: PSA
ENGINE: 2.2L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
CAPACITANCE: 2.1-3.1 Uf @ 20C
S3000 Common Rail
Test System
TEST DATA
M
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables (T031-3003R).
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System &
Check for Leaks
1000 1450 1200 112-116 <40.0 60.0 Max Fuel
1000 1450 900 78-82 Mid Range
1000 1450 700 54-60 - - Low Speed
1000 500 700 22-24 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
INJECTOR DATA
PART No: 0 445 115 028
TYPE: CR/IPS19/ZEREAK50S
O.E.M. REF: VW
ENGINE: 2.5L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
CAPACITANCE: 2.1-3.1 Uf @ 20C
S3000 Common Rail
Test System
TEST DATA
M
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables.(T031-3201R)
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System &
Check for Leaks
1000 1450 1200 100-110 <40.0 60.0 Max Fuel
1000 1450 900 65-75 Mid Range
1000 1450 700 45-55 - - Low Speed
1000 500 700 20-25 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
INJECTOR DATA
PART No: 0 445 115 069
TYPE: CR/IFL19/ZEREAK50S
O.E.M. REF: MERCEDES SPRINTER
ENGINE: 2.1L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
CAPACITANCE: 2.1-3.1 Uf @ 20C
S3000 Common Rail
Test System
TEST DATA
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables.(T031-3201R)
Attach Bosch return pipe (0 986 612 922).
Switch S3000 to Piezo.
Close protective cover.
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System &
Check for Leaks
1000 1450 1200 110-120 <40.0 60.0 Max Fuel
1000 1450 900 75-85 Mid Range
1000 1450 700 55-65 - - Low Speed
1000 500 700 22-27 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
INJECTOR DATA
PART No: 0 445 115 070
TYPE: -
O.E.M. REF: BMW 3.0
ENGINE: 2.1L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
CAPACITANCE: 2.1-3.1 Uf @ 20C
S3000 Common Rail
Test System
TEST DATA
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Injector Designation:- 0 445 120 002
Type Designation:- CR/IPS21/ZIREK10S
Manufacturer I.D.:- IVECO 500313105
Engine:- 8140-43
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
92-97
<35.0/55.0 Max Fuel
400 250 700
16.0-19.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 120 003/004
Type Designation:- CR/IPL32ZIRIS10S
Manufacturer I.D.:- RVI 50 10 412 093
Engine:- 420DCi 303 Kw >2001
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
150-165
<35.0/55.0 Max Fuel
400 250 700
25.0-28.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3901.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 82-87 <35.0 55.0 Max Fuel
400 250 700 12-18 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 120 007
TYPE: CR/IFS26/ZIRIS10S
O.E.M. REF: CDC 4897271
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 120 011
Type Designation:- CR/IPS19/ZEREK10S
Manufacturer I.D.:- IVECO 500371101
Engine:- F1AE-0481
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
80-84
<35.0/55.0 Max Fuel
400 250 700
16.0-18.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 120 020
Type Designation:-
Manufacturer I.D.:-
Engine:- ISB
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
115-125
<35.0/55.0 Max Fuel
400 250 700
12.0-13.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 120 028
Type Designation:- CR/IFL26/ZIRIS10S
Manufacturer I.D.:- IVECO 504055805
Engine:- CSC ISB
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
100-110
<35.0/55.0 Max Fuel
400 250 700
12.0-14.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 120 030
Type Designation:-
Manufacturer I.D.:-
Engine:- QSB
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
155-167
<35.0/55.0 Max Fuel
400 250 700
5.0-7.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3901.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 100-110 <35.0 55.0 Max Fuel
400 250 700 8-12 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 120 040
TYPE: CR/IPL26/ZIRIS10S
O.E.M. REF: -
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 120 054
Type Designation:- CR/IFl26/ZIRIS20S
Manufacturer I.D.:- IVECO 504091504
Engine:- QSB
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
100-110
<35.0/55.0 Max Fuel
400 250 700
13.0-15.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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Injector Designation:- 0 445 120 057
Type Designation:- CR/IFS26/ZIRIS20S
Manufacturer I.D.:- IVECO 504091505
Engine:- QSB
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
100-110
<35.0/55.0 Max Fuel
400 250 700
15.0-17.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipes.
Attach injector cables T031-3901.
Close protective cover.
Pump
Speed
RPM
Rail
Pressure
BAR
Pulse
Width
Delivery
cc/1000
Max Back Leak
cc/1000 cc/min
Comments
1000 1000 700 N/A
- -
Purge System & Check for
Leaks
1500 1350 900 95-100 <35.0 55.0 Max Fuel
400 250 700 12-14 <20.0 9.0 Idle
2000 1350
Run pump
only
N/A <12.5 25.0 Seat Test
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA
PART No: 0 445 120 064
TYPE: CR/IPL28/ZIRIS20S
O.E.M. REF: RENAULT
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40C
SOLENOID RESISTANCE @ 20C - 600m
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Injector Designation:- 0 445 120 210
Type Designation:-
Manufacturer I.D.:-
Engine:- ISB
Testing Prerequisites
Mount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20C - 600 m
S3000 Common Rail
Test System
TEST DATA
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3901 and metering pipes to
injectors. Close protective cover.
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
Remove Fuel Connection T031-3052. 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.
Note:-
When calibrating more than one injector of the same number ensure that all flow
rates are matched through the set.
Pump Speed
RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
1500 1350 900
75.0-80.0
<35.0/55.0 Max Fuel
400 250 700
10.0-13.0
<20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
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