delphi pump test plans 4 web
TRANSCRIPT
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MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9042A0013A-014A
Type Designation:-0.6CC2
Manufacturer I.D.:- RENAULT
Engine:-
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit In line return temperature sensor to return line. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9 MER
LIN D
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L SYS
TEMS
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MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 500-600 2 1000 60 0 3 1000 80 500-600
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - N/A 5.0-6.0 20
2 - N/A 5.5-6.5 40
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600 440
2 2000 1600 475-525
3 1000 1200 475-525
4 1000 500 560 10% 5 1000 1000 Max 10% less 450-500
6 50 230 450+
MERL
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LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9042A021A-023A
Type Designation:-0.6CC2
Manufacturer I.D.:- PSA
Engine:- DV4 1.4HDi 90HP
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit In line return temperature sensor to return line. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9 MER
LIN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 500-600 2 1000 60 0 3 1000 80 500-600
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - N/A 5.0-6.0 20
2 - N/A 5.5-6.5 40
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600 440
2 2000 1600 475-525
3 1000 1200 475-525
4 1000 500 560 10% 5 1000 1000 Max 10% less 450-500
6 50 230 450+
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9042A041A
Type Designation:-0.6CC2
Manufacturer I.D.:- RENAULT
Engine:-
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit In line return temperature sensor to return line. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9 MER
LIN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 500-600 2 1000 60 0 3 1000 80 500-600
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - N/A 5.0-6.0 20
2 - N/A 5.5-6.5 40
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600 440
2 2000 1600 475-525
3 1000 1200 475-525
4 1000 500 560 10% 5 1000 1000 Max 10% less 450-500
6 50 230 450+
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044A070A
Type Designation:-1.2CC2
Manufacturer I.D.:- KIA/HYUNDAI
Engine:- 2.9L
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 130 BAR 1150-1250 2 1000 60 0 3 1000 80 1150-1250
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
2 - 0.9-1.5 5.5-6.5 40
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2000 1600 760-840
2 1000 1200
3 1000 500 980 10% 4 1000 1000 Max 10% less >900
5 50 230 >1000
MERL
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MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044A071A
Type Designation:-1.2CC2
Manufacturer I.D.:- KIA/HYUNDAI
Engine:- 2.9L
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 130 BAR 1150-1250 2 1000 60 0 3 1000 80 1150-1250
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
2 - 0.9-1.5 5.5-6.5 40
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2000 1600 760-840
2 1000 1200
3 1000 500 980 10% 4 1000 1000 Max 10% less >900
5 50 230 >1000
MERL
IN D
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L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044A072A
Type Designation:-1.2CC2
Manufacturer I.D.:- KIA/HYUNDAI
Engine:- 2.9L
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 130 BAR 1150-1250 2 1000 60 0 3 1000 80 1150-1250
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
2 - 0.9-1.5 5.5-6.5 40
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2000 1600 760-840
2 1000 1200
3 1000 500 980 10% 4 1000 1000 Max 10% less >900
5 50 230 >1000
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z013A
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD LYNX
Engine:- 1.8TDCI
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z015A
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD LYNX
Engine:- 1.8TDCI
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
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MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z016A/B
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD LYNX
Engine:- 1.8TDCI FOCUS 115HP CONNECT 90HP
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z020A
Type Designation:-0.9CC2
Manufacturer I.D.:- KIA/HYUNDAI
Engine:- 2.9L TCI 149HP
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z022A
Type Designation:-0.9CC2
Manufacturer I.D.:- KIA/HYUNDAI
Engine:- 2.9L TCI 149HP
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z032A
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD
Engine:- LYNX 2.0TDCi 16V
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z033A
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD
Engine:- LYNX 2.0TDCi 16V
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z034A
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD
Engine:- PUMA 2.0TDCi 16V
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z035A
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD/JAGUAR
Engine:- LYNX 2.0TDCi 16V
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z080A
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD
Engine:- PUMA 2.4TDCI
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z090A
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD
Engine:- PUMA 2.0TDCi 16V EURO3 2.2TDCi 150HP EURO4
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z100A
Type Designation:-0.9CC2
Manufacturer I.D.:- Ford
Engine:- Mondeo 2.0 TDCi 150HP Euro4
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail Test System
TEST DATA
Pump Designation:-9044Z130A
Type Designation:-0.9CC2
Manufacturer I.D.:- FORD/JAGUAR
Engine:- PUMA 2.0TDCI EURO 4 130/155HP
Testing PrerequisitesInlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005 Fit Transfer pressure adaptor T016-697 in place of Temperature sender and re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge. Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872). Connect Fuel Pump Cable T031-3001 to PCV in test rail. Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST To be Carried out whenever rollers and shoes have been disturbed or replaced
Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8 5 2000 1200 60 9
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001. Set S3000 Test Unit to PCV
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV Leave Bosch type PCV in rail (ie 0281002872) Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test Bench Speed - RPM SCV DRV % Comments Delivery CC/1000
1 1000 80 800-900 2 1000 60 0 3 1000 80 800-900
Test Bench Speed - RPM Temp Sender Resistance K
SCV Resistance
INLET FUEL TEMP C
1 - 2.5-4.0 5.0-6.0 20
Test Bench Speed - RPM Rail Pressure BAR
Comments Delivery CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10% 5 1000 1000 Max 10% less 700
6 50 230 760+
MERL
IN D
IESE
L SYS
TEMS
LTD
-
MERLIN S3000 COMMON RAIL TEST SYSTEM
2 - 0.9-1.5 5.5-6.5 40
MERL
IN D
IESE
L SYS
TEMS
LTD
9042A013A-014A9042A021-023A9042A041A9044A070A9044A071A9044A072A9044Z013A-B9044Z015A-B9044Z016A-B9044Z020A9044Z022A9044Z032A9044Z033A9044Z034A9044Z035A9044Z080A9044Z090A9044Z100A9044Z130A