test data - merlin diesel systems ltd · injector data part no: 5ws-40057 type: a2c59511315 o.e.m....
TRANSCRIPT
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 92-98 <60.0 <90.0 Max Fuel
1500 1200 1200 62-68 High Mid Range
1500 800 600 32-39 Mid Range
1500 400 600 17-23 Light Load
400 250 700 11-15 Idle
400 150-250 700 N/A S.O.I
400 800 100 0.5-4.0 Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: BK2Q-9K546-AG
TYPE: -
O.E.M. REF: FORD
ENGINE: TRANSIT 2.2/2.4 TDCI
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 77-82 <60.0 <90.0 Max Fuel
1500 1200 1200 60-63 High Mid Range
1500 800 600 25-30 Mid Range
1500 400 600 18-22 Light Load
400 250 700 13-15 Idle
400 150-250 700 N/A S.O.I
400 800 80 1.0-3.0 Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40000Z
TYPE: -
O.E.M. REF: PSA 9636680280 1980.F0
ENGINE: DW10 BTED 2.0HDi 64kW
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 85-88 <60.0 <90.0 Max Fuel
1500 1200 1200 58-61 High Mid Range
1500 800 600 27-30 Mid Range
1500 400 600 18-20 Light Load
400 250 700 10-12 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40057
TYPE: A2C59511315
O.E.M. REF: FORD 4S7Q 9K546 AF
ENGINE: JAGUAR 2.7V6
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width
Delivery cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1500 1000 - - - Purge System & Check for Leaks
1000 1500 800 42-48 <60 <60.0 Max Power
1000 1150 1200 57-63 - - Max Torque
1000 1000 700 30-36 - - Emissions
1000 850 120 0.5-2.5 - - Pre-Injection
400 250 500 4-8 - - Idle
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40086
TYPE: A2C59511610
O.E.M. REF: FORD
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 55-60 <60.0 <90.0 Max Fuel
1500 1200 1200 N/A High Mid Range
1500 800 600 N/A Mid Range
1500 400 600 N/A Light Load
400 250 700 6-8 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40087
TYPE: A2C59511606
O.E.M. REF: REN K9KIAM VERS
ENGINE: K9K
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 85-88 <60.0 <90.0 Max Fuel
1500 1200 1200 58-62 High Mid Range
1500 800 600 27-30 Mid Range
1500 400 600 16-18 Light Load
400 250 700 11-12 Idle
400 150-250 700 N/A S.O.I
400 800 100 -- Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40103
TYPE: A2C59511316
O.E.M. REF: FORD 5U3Q 9K546 AA
ENGINE: LION V6 EURO 4 JAGUAR & PSA
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width
Delivery cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1500 1000 - - - Purge System & Check for Leaks
1000 1500 800 30-36 <60 <60.0 Max Power
1000 1150 1200 44-50 - - Max Torque
1000 1000 700 23-29 - - Emissions
1000 850 120 0.5-2.5 - - Pre-Injection
400 250 500 3-7 - - Idle
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40148Z (5WS-40007)
TYPE: -
O.E.M. REF: FORD 2S6Q9F593AB
PSA 1980.E7
ENGINE: DV41.4HDi 50Kw EURO 3
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width
Delivery cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1500 1000 33-39 - - Purge System & Check for Leaks
1000 1500 800 29-34 <60 <60.0 Max Power
1000 1150 1200 36-41 - - Max Torque
1000 1000 700 24-29 - - Emissions
1000 850 100 0.5-2.0 - - Pre-Injection
400 250 600 5-8 - - Idle
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40149-Z
TYPE: A2C59511612
O.E.M. REF: FORD, PSA EURO 4
ENGINE: 1.4 L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 82-86 <60.0 <90.0 Max Fuel
1500 1200 1200 57-63 High Mid Range
1500 800 600 26-30 Mid Range
1500 400 600 15-20 Light Load
400 250 700 10-12 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40156-4Z
TYPE: -
O.E.M. REF: FORD FOCUS 1.8 EURO 4
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width
Delivery cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1500 1000 - - - Purge System & Check for Leaks
1000 1500 800 43-49 <60 <60.0 Max Power
1000 1150 1200 55-61 - - Max Torque
1000 1000 700 33-39 - - Emissions
1000 850 120 0.5-2.5 - - Pre-Injection
400 250 500 5-8 - - Idle
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40156Z
TYPE: - O.E.M. REF: FORD 1373550 PSA 9659244280 VOLVO 8603564 ENGINE: DW10 2.0HDI 100KW (CLASS 5)
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 88-92 <60.0 <90.0 Max Fuel
1500 1200 1200 60-63 High Mid Range
1500 800 600 30-34 Mid Range
1500 400 600 12-14 Light Load
400 250 700 8-9.5 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40200
TYPE: A2C59511602
O.E.M. REF: PSA 1980K5
ENGINE: PSA DW10 2.0 HDi 100KW
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 76-81 <60.0 <90.0 Max Fuel
1500 1200 1200 52-57 High Mid Range
1500 800 600 27-30 Mid Range
1500 400 600 15-17 Light Load
400 250 700 8-10 Idle
400 150-250 700 N/A S.O.I
400 800 100 0.5-2.0 Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40249
TYPE: A2C59511364
O.E.M. REF: LAND ROVER LR006495
ENGINE: DT17 2.7 V6
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width
Delivery cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1500 1000 - - - Purge System & Check for Leaks
1000 1500 800 33-39 <60 <60.0 Max Power
1000 1150 1200 37-43 - - Max Torque
1000 1000 700 22-28 - - Emissions
1000 850 120 0.5-2.5 - - Pre-Injection
400 250 500 3-7 - - Idle
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Set to 100RPM and 700 pulse width. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks.
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40250
TYPE: A2C59511611
O.E.M. REF: FORD 1432322
ENGINE: LYNX 1.8 TDCI 85-92KW
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 75-80 <60.0 <90.0 Max Fuel
1500 1200 1200 N/A High Mid Range
1500 800 600 N/A Mid Range
1500 400 600 N/A Light Load
400 250 700 10-12 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40252
TYPE: A2C59513553
O.E.M. REF: LANDROVER
ENGINE: LION V6 UG
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1200 65-70 <60.0 <90.0 Max Fuel
1500 1200 900 45-50 High Mid Range
1500 800 600 29-31 Mid Range
1500 400 400 8-9 Light Load
400 250 700 10-11 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40253
TYPE: -
O.E.M. REF: 6H4Q-9K-546CB
ENGINE: FORD/ PSA LION V6
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1200 65-70 <60.0 <90.0 Max Fuel
1500 1200 900 45-50 High Mid Range
1500 800 600 29-31 Mid Range
1500 400 400 8-9 Light Load
400 250 700 10-11 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40387
TYPE: A2C59513597
O.E.M. REF: 6H4Q-9K-546CB
ENGINE: FORD/ PSA LION V6
R/ROVER SPORT 3.6L V8
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 77-80 <60.0 <90.0 Max Fuel
1500 1200 1200 55-58 High Mid Range
1500 800 600 27-30 Mid Range
1500 400 600 12-14 Light Load
400 250 700 7.5-9 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40441
TYPE: A2C59511603
O.E.M. REF: PSA 1980K8
ENGINE: PSA DW10 2.0 HDi 100KW
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 87-93 <60.0 <90.0 Max Fuel
1500 1200 1200 57-63 High Mid Range
1500 800 600 27-32 Mid Range
1500 400 600 14-18 Light Load
400 250 700 8-12 Idle
400 150-250 700 N/A S.O.I
400 800 100 0.5-4 Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40516
TYPE: A2C59511612
O.E.M. REF: PSA 9663429280
ENGINE: DV4 TD
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1200 62-68 <60.0 <90.0 Max Fuel
1500 1200 900 47-53 High Mid Range
1500 800 600 27-33 Mid Range
1500 400 440 10-14 Light Load
400 250 700 10-14 Idle
400 150-250 700 N/A S.O.I
400 800 100 - Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40539
TYPE: A2C59513554
O.E.M. REF: VW/AUDI/SKODA
ENGINE: 1.6L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3201R. Close protective cover. Switch S3000 to Piezo.
IMPORTANT:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE AND INSULATION TEST CARRIED OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
Pump 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 Leaks1500 1600 1600 77-82 <60.0 <90.0 Max Fuel
1500 1200 1200 60-63 High Mid Range
1500 800 600 32-36 Mid Range
1500 400 600 22-24 Light Load
400 250 700 14-18 Idle
400 150-250 700 N/A S.O.I
Pre Injection
Start of Injection Stop Test Bench. Reduce Rail Pressure on S3000 to Zero. Remove Fuel Connection. Close Protective cover. Run Test Bench to 400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes. Rail pressure should be 150-200BAR.
Dry Seat Test Select pump only on S3000. Remove nozzle sleeve and adaptor cable from injector. Running at 100RPM, 1000BAR and zero pulse width visually check nozzle tip for leaks
Note:- When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
INJECTOR DATA
PART No: 5WS-40677
TYPE: A2C59513556
O.E.M. REF: PSA/ FORD/MAZDA/VOLVO
ENGINE: 1.5L (82kW)
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
CAPACITANCE: 3.0-4.5 Uf @ 20°C
S3000 Common Rail Test System
TEST DATA