tabel test cr i by merlin

8/13/2019 Tabel Test CR i by Merlin

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MERLIN DIESEL SYSTEMS LTD

189-191, Bradkirk Place, Walton Summit CentrePreston, Lancashire, PR5 8AJ, England

Tel: +44 (0)1772 694180 Fax: +44 (0)1772 314565E: [email protected] W: www.merlindiesel.com

Pumps Parts Test Equipment Filters New Generation Workshops Diagnostic & Vehicle Care Centre

FOR MORE INFORMATION PLEASE CALL 01772 694180

T016- 852

Digital External MicrometerRange: 0-25mm Resolution: 0.001mm

T016- 848

40x MagnifierT021- 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 injectorsincluding:-

CRI 2.1 AND CRIN 1, 2 & 3

Consists of:-

T021- 956Dial gauge holder kitFor measuring ball bearing stroke on allBosch common rail injectors.Supplied with 17 & 19mm adaptors

S350

Armature stroke test unit c/w 3 adaptorcables

T016- 850

Digital dial indicator 12.5/0.001mmRange: 12.500 mmResolution: 0.001 mm

T021- 957

Pin for T016-850 & T021-956

All parts are available separately

IMPORTANTIT 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.


2/126

Injector Designation:- 0 445 110 002

Type Designation:- CR/IPS19/ZEREK10S

Manufacturer I.D.:- FIAT 46472233

Engine:- 182 B 4000 1.9 JTD

Testing PrerequisitesMount Suitable Test Pump

Test Oil Specification- ISO 4113

Test Oil Temperature- 40 C

Solenoid Resistance @ 20C - 600 m

S3000 Common RailTest System

TEST DATA

Start of Injection (S.O.I)

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, closecover and SLOWLY increase pressure as per test.Note:-When calibrating more than one injector of the same number ensure that all flowrates are matched through the set.

Pump SpeedRPM

Rail PressureBAR

Pulse Width Deliverycc/1000

Max Back LeakMm3st/ccmin

Comments

1000 1000 1200 N/A - PurgeSystem

2000 1500 1200 N/A - Check forLeaks

1500 1350 900 50-55


3/126


Type Designation:- CR/IPS19/ZERAK10S

Manufacturer I.D.:- DB 611 070 05 87

Engine:- OM611-961/980






TEST DATA

Remove all washers from injectorsFit Injectors to Injector rack. Attach cables T031-3201 and metering pipes toinjectors. Close protective cover.

Start of InjectionStop Test Bench. Reduce Rail Pressure on S3000 to Zero.Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emittingfrom 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 SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 73-77


4/126

Injector Designation:- 0 445 110 0150 986 435 005

Type Designation:- CR/IPS19/ZEREAK20S


Engine:- OM668-941






TEST DATA





Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 52-57


5/126




Engine:- 188 A 2.000 1.9JTD

Testing Prerequisites

Mount Suitable Test Pump




TEST DATA

Remove all washers from injectorsFit Injectors to Injector rack. Attach cables T031-3003 and metering pipes toinjectors.Close protective cover.


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

Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 60-65


6/126



Manufacturer I.D.:- RENAULT 7700 107 165

Engine:- F9Q 1.9DCi






TEST DATA





Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 64-69


7/126




Engine:- OM611-961 611-981






TEST DATA





Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 65-70


8/126


Type Designation:- CR/IFS17/ZERAK10S

Manufacturer I.D.:- BMW 13 53 7 785 437

Engine:- 30 6 D1 3.0D






TEST DATA





Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 61-66


9/126




Engine:- 30 4 D1 2.0D






TEST DATA





Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 55-60


10/126




Engine:- OM611.981 OM611.987






TEST DATA



Note:-

When calibrating more than one injector of the same number ensure that all flowrates are matched through the set.

Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 71-76


11/126


Type Designation:- CR/IFS17/ZEREW10S

Manufacturer I.D.:- PSA 96533448

Engine:- PSA2.2HDi 4HX






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90062-66


12/126

Remove all washers from injectors.Fit injectors to rack.Fit injector pipe.Attach injector cables T031-3003.Close protective cover.

PumpSpeedRPM

RailPressure

BAR

PulseWidth Deliverycc/1000

Max Back Leak

cc/1000 cc/minComments

1000 1000 700 N/A - - Purge System & Check for

Leaks1500 1350 900 76-78


13/126



Manufacturer I.D.:- PSA 96375360/1980-72

Engine:- 2.0 HDi






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90057-60


14/126


Type Designation:- CR/IFS17/ZEREK10S

Manufacturer I.D.:- BMW 13 53 778 984

Engine:- 30 6 D1






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90070-72


15/126


Type Designation:- CR/IFS17/ERAK10S


Engine:- 25 6D1







TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 55-60


16/126



Manufacturer I.D.:- BMW 1353 7 785 983

Engine:-






TEST DATA




Pump SpeedRPM

Rail PressureBAR


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


17/126


Type Designation:- CR/IPL19/ZERAK20S


Engine:- OM646-951/961





TEST DATA

Remove all washers from injectorsFit Injectors to Injector rack. Attach cables T031-3201and metering pipes toinjectors. Close protective cover.



Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90073-77


18/126



Manufacturer I.D.:- PSA 1980-78

Engine:- RHW 2.0HDi 16v






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 55-60


19/126



Manufacturer I.D.:- VM 1506 2036F

Engine:- 2.5CRD





TEST DATA


Start of InjectionStop Test Bench. Reduce Rail Pressure on S3000 to Zero.Remove Fuel Connection T016-3052 Close Protective cover. Run Test Bench to400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emittingfrom nozzle holes. Rail pressure should be 150-200BAR.


Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 80-83


20/126




Engine:- PSA 2.0HDi RHY






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90060-64


21/126



Manufacturer I.D.:- RENAULT 8200010075

Engine:- 1.9 DCi






TEST DATA



Note:-


Pump SpeedRPM

Rail PressureBAR


Comments



1500 1350 900 55-60 Max Fuel

400 250 700 10.0-12.0 Idle1500 1350 900


22/126



Manufacturer I.D.:- HYUNDAI 33800-27000

Engine:- D3EA/D4EA






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90065-68


23/126




Engine:- 182 B 9.000/ 186 A 6.000 1.9JTD






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 77-80


24/126




Engine:- OM611-981/OM611-987






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 72-75


25/126



Manufacturer I.D.:- 611 070 08 07

Engine:- OM611.981 / 987






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90072-75


26/126




Engine:- OM611-962






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90064-68


27/126


Type Designation:- CR/IPL20/ZEREAK20S


Engine:- 8HX / 8HZ






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90043-47


28/126




Engine:- PSA2.0HDi RHS/RHY






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90060-64


29/126



Manufacturer I.D.:- VOLVO 8658350

Engine:- D5244T






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 69-71


30/126


Type Designation:- CR/IFL17/ZEREAK20S


Engine:- 20 4 D4 / 30 6 D2






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90080-84


31/126


Type Designation:-

Manufacturer I.D.:-

Engine:-






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 84.0-87.0


32/126




Engine:- 1.3JTD /OPEL 1.3CDTI






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 65-70


33/126


Type Designation:- CR/IFL19/ZERAK10S


Engine:- REN 2.2 DCi 110KW G9T-742






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 68-73


34/126




Engine:- REN 1.9 DCi OPEL 1.9 DTi






TEST DATA



Note:-


Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 77-80


35/126




Engine:- OM668-914






TEST DATA



Note:-


Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90056-60


36/126



Manufacturer I.D.:- HYUNDAI 33800-4A000

Engine:- D4CB 2.5CRDI






TEST DATA



Note:-


Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 78-84


37/126




Engine:- OM628-962






TEST DATA



Note:-


Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90067-71


38/126




Engine:- OM611-981 / OM611-987






TEST DATA



Note:-


Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90075-78


39/126



Manufacturer I.D.:- OM612.965

Engine:- MB






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 70-75


40/126



Manufacturer I.D.:- OM612.965

Engine:- MB






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 70-75


41/126




Engine:- OM611-962






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90067-72


42/126


Type Designation:- CR/IPL17/ERAK10S

Manufacturer I.D.:- HYUNDAI 33800-27000

Engine:- D3EA/D4EA






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90067-72


43/126


Type Designation:- CR/IFS19/ERAK10S


Engine:- G9T-722 / G9T-750 2.2DCi






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 57-62


44/126




Engine:- OM611-981 OM644-987






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90073-77


45/126




Engine:- OM611-981 OM644-987






TEST DATA



Note:-


Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90073-77


46/126




Engine:- 1.9 DCi






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90064-67


47/126



Manufacturer I.D.:- Fiat 55192534

Engine:- 192 B / 537 A






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90085-90


48/126




Engine:- 1.9JTD 8V






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 85-90


49/126



Manufacturer I.D.:- VW 057130276H

Engine:- AKF3.3TDi






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 62-67


50/126




Engine:- OM668-940






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90056-60


51/126


Type Designation:- CR/IPL17/ERAK20S

Manufacturer I.D.:- OPEL 97300091

Engine:- Z17DTL






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 50-55


52/126




Engine:- 1.9JTD 8V






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 80-85


53/126




Engine:- OM611-962 / OM612-962






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90070-72


54/126



Manufacturer I.D.:- MWM 94 070 46 4 0024

Engine:-






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 80-85


55/126


Type Designation:- CR/IFS17/ZEREK10S


Engine:-






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90052.5-57.5


56/126


PumpSpeedRPM

RailPressure

BAR


Max Back Leak


1000 1000 700 N/A- -

Purge System & Check for

Leaks1500 1350 900 105-115


57/126




Engine:- 1.4HDi 8HX/8HZ






TEST DATA


Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emittingfrom nozzle holes. Rail pressure should be 150-200BAR.


Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90041-45


58/126


Type Designation:- CR/IFL17/ZEREK20S

Manufacturer I.D.:- FORD 3M5Q 9F593 CA

Engine:- 1.6 TDCI






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 47-50


59/126

Injector Designation:- 0 445 110 139/140



Engine:- OM646-982






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90081-86


60/126




Engine:- G9U-724 / G9U-754 2.5DCi






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 92-95


61/126




Engine:- F9Q 820






TEST DATA



Note:-


Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90064-69


62/126




Engine:- 20 4 D 4 1.8D






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 55-60


63/126


PumpSpeedRPM

RailPressure

BAR


Max Back Leak



Leaks1500 1350 900 70-75


64/126



Manufacturer I.D.:- VW 057 130 277 L

Engine:- ASE 4.0 TDI






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 75.0-80.0


65/126




Engine:- Z19 DTH






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 95-99


66/126


PumpSpeedRPM

RailPressure

BAR


Max Back Leak


1000 1000 700 N/A- -


Leaks1500 1350 900 97-103


67/126


Type Designation:- CR/IPL19/ZEREK20S

Manufacturer I.D.:- VAUXHALL/OPEL

Engine:- 1.9 CDTI






TEST DATA



Note:-


Pump SpeedRPM

Rail PressureBAR


Comments



1500 1350 900 80-85 Max Fuel

400 250 700 3.0-6.0 Idle1500 1350 900


68/126



Manufacturer I.D.:- NISSAN 16600 DB 000

Engine:- 1.6 HDi -






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 95-100


69/126


PumpSpeedRPM

RailPressure

BAR


Max Back Leak


1000 1000 700 N/A- -


Leaks1500 1350 900 112-118


70/126


PumpSpeedRPM

RailPressure

BAR


Max Back Leak



Leaks1500 1350 900 54-60


71/126


Type Designation:- CR/IPl17/ZEREK20S

Manufacturer I.D.:- OPEL 897 363 812

Engine:- OM648






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments


2000 1500 1200 N/A - Check for

1500 1350 900 58-64


72/126




Engine:- OM648






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 90064-70


73/126


74/126




Engine:- Z13 DTH






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 68-72


75/126

Injector Designation:- 0 445 110 186/279


Manufacturer I.D.:- HYUNDAI 33800 4A100

Engine:- D4CB 2.5Lt






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 88.0-93.0


76/126




Engine:- 1.3JTD 8V






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 70-75


77/126



Manufacturer I.D.:- PSA 1980-H3

Engine:- 1.6 HDi - FORD 1.6 TDCi






TEST DATA




Pump SpeedRPM

Rail PressureBAR



Comments



1500 1350 900 52-55


78/126




Engine:- OM611-981 OM644-987




Solenoid Resistance @ 20C -

tabel test cr i by merlin

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