S3000 Common Rail

Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 002
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 1S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 4645 2567
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 560/56

LI

2 500 300 600/300

3 1000 500 600/600
ER

4
5 1000 1000 Max 10% less More Than
than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 003
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 1S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 4643 2242
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 560/56

LI

2 500 300 600/300

3 1000 500 600/600
ER

4
5 1000 1000 Max 10% less More Than
than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 006
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 1S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FIAT 4652 2786
Test Oil Temperature- 40 C

EM
Engine:- 185A 6 000 2.4JTD
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

N

Mm3st/ccmin
1 100 300 560/56
LI

2 500 300 600/300

3 1000 500 600/600
ER

4
5 1000 1000 Max 10% less More Than
than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 007
Inlet Feed Pressure - 1.5 BAR
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 540/54

LI

2 500 300 510/225

3 1000 500 510/510
ER

4 1000 1000 340/340

5 1000 1000 Max 10% less More Than
than 3 540/540
M

6 2000 1350 510/1020

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 008
Inlet Feed Pressure - 1.5 BAR
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031-3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031-3051 to Fuel Pump.
Connect Fuel Pump Cable T031-3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 550/275

3 1000 500 550/550
ER

4
5 1000 1000 Max 10% less More Than
than 3 500/500
M

6 2000 1350 550/1100

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 009
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R70/10- 1S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 13 51 2 247 798
Test Oil Temperature- 40 C

EM
Engine:- 30 6 D1
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 640/320

3 1000 500 650/650
ER

4
5 1000 1000 Max 10% less More Than
than 3 580/580
M

6 2000 1350 600/1200

3. RESISTANCES

MERLIN S3000 COMMON RAIL TEST SYSTEM

 Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 - 20

2 - 3.5-3.7 - 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 010
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 16S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1920 CY
Test Oil Temperature- 40 C

EM
Engine:- PSA RHY/RHZ 2.0 HDi
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 560/56

LI

2 500 300 600/300

3 1000 500 600/600
ER

4 1000 500 Activate Aux >400/400

Button

5 1000 1000 Max 10% less More Than

than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 011
Inlet Feed Pressure - 1.5 BAR
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N
LI

1 500 300 510/255

2 1000 500 510/510
ER

3 1000 500 Activate Aux n/a

Button

4 1000 1000 Max 10% less More Than

than 3 460/460
M

5 2000 1350 510/1020

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 013
Inlet Feed Pressure - 1.5 BAR
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031-3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031-3051 to Fuel Pump.
Connect Fuel Pump Cable T031-3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 550/275

3 1000 500 550/550
ER

4
5 1000 1000 Max 10% less More Than
than 3 500/500
M

6 2000 1350 550/1100

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 018
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 1S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 7700101016
Test Oil Temperature- 40 C

EM
Engine:- F9Q- 732 1.9 DCi Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

N

mm3st/ccmin
1 100 300 560/56
LI

2 500 300 600/300

3 1000 500 600/600
ER

4
5 1000 1000 Max 10% less More Than
than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 019
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1K3/L70/10- 6S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 612 070 00 01
Test Oil Temperature- 40 C

EM
Engine:- OM612- 961/962/963/967
Direction of Rotation - L

ST
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 640/320

3 1000 500 650/650
ER

4
5 1000 1000 Max 10% less More Than
than 3 580/580
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES

Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 - 20

2 - 3.5-3.7 - 40

D
- -

LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 021
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R70/10- 16S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1920 AL
Test Oil Temperature- 40 C

EM
Engine:- PSA 4HX /RHW 2.2 HDi
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 640/320

3 1000 500 650/650

ER

4 1000 500 Activate Aux >420/420

Button
5 1000 1000 Max 10% less More Than
than 3 580/580
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 024
Inlet Feed Pressure - 1.5 BAR
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031-3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031-3051 to Fuel Pump.
Connect Fuel Pump Cable T031-3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 550/275

3 1000 500 550/550
ER

4
5 1000 1000 Max 10% less More Than
than 3 500/500
M

6 2000 1350 550/1100

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 028
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/L70/10- 1S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200 010 076
Test Oil Temperature- 40 C

EM
Engine:- G9T- 710 2.2DCi
Direction of Rotation - L

ST
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 640/320

3 1000 500 650/650
ER

4
5 1000 1000 Max 10% less More Than
than 3 580/580
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES

Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 - 20

2 - 3.5-3.7 - 40

D
- -

LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 029
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L110/30- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 628 070 01 01
Test Oil Temperature- 40 C

EM
Engine:- OM628.960/961
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
1 100 300 970/97
2 500 300 1100/550
3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Cm/1000
S

1 1000 NOM Pump Drv 100% 1100/1100

2 1000 NOM Pump Drv 50% Nil
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 030
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1K3/L70/10- 6S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 612 070 01 01
Test Oil Temperature- 40 C

EM
Engine:- OM612- 981
Direction of Rotation - L

ST
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV And shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 640/320

3 1000 500 650/650
ER

4 1000 500 Activate Aux <420/420

Button

5 1000 1000 Max 10% less More Than

than 3 580/580
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES

Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40

D
- -

LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 031
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200 037 472
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv Nil

50%
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 032
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1K3/L70/10- 6S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 612 070 02 01
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV And shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 640/320

3 1000 500 650/650
ER

4 1000 500 Activate Aux <420/420

Button

5 1000 1000 Max 10% less More Than

than 3 580/580
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES

Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40

D
- -

LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Pump Designation:- 0 445 010 033 Testing Prerequisites

LT
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/
0- 8911S Test Oil Specification- ISO 4113
Manufacturer I.D.:-

S
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580

S
5 2000 1350 600/1200

EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 034
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- VM 3502 2087F
Test Oil Temperature- 40 C

EM
Engine:- CHRYSLER 2.5CRDI
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 038
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1K3/R70/10S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- HYUNDAI 33100 27000
Test Oil Temperature- 40 C

EM
Engine:- D4EA
Direction of Rotation - R

ST
Fit T016- 693 fuel inlet kit to pump.
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type PCV to test rail (ie 0281002873).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 640/320

3 1000 500 650/650
ER

4
5 1000 1000 Max 10% less More Than
than 3 580/580
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES

Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 - 20

2 - 3.5-3.7 - 40

D
- -

LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 039
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- ISUZU 897227 0264
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 042
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1920 EC 96373173
Test Oil Temperature- 40 C

EM
Engine:- 8HX / 8HZ
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 045
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 89S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 1351 7 787199
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 046
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 16S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1920 EA
Test Oil Temperature- 40 C

EM
Engine:- PSA RHY/RHS 2.0 HDi
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
N

1 100 300 560/56

LI

2 500 300 600/300

3 1000 500 600/600
ER

4 1000 500 Activate Aux >400/400

Button

5 1000 1000 Max 10% less More Than

than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 047
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA
Test Oil Temperature- 40 C

EM
Engine:- D- 4D 1.4
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv Nil

50%
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 048
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 89S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB611 070 14 01
Test Oil Temperature- 40 C

EM
Engine:- OM646- 962/982
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 052
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- KIA/HYUNDAI
33100- 4A000 Test Oil Temperature- 40 C

EM
Engine:- D4CB
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 071
Inlet Feed Pressure - 1.5 BAR
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 540/54

LI

2 500 300 510/225

3 1000 500 510/510
ER

4 1000 1000 340/340

5 1000 1000 Max 10% less More Than
than 3 540/540
M

6 2000 1350 510/1020

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 072
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 1S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- LANCIA 75301003
Test Oil Temperature- 40 C

EM
Engine:- 841 M 000 THESIS 2.4 JTD
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

N

mm3st/ccmin
1 100 300 560/56
LI

2 500 300 600/300

3 1000 500 600/600
ER

4
5 1000 1000 Max 10% More Than
less than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 075
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200 108 225
OPEL 9109268 Test Oil Temperature- 40 C

EM
Engine:- 1.9DCI
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv Nil

50%
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 076
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- ISUZU 897227 0264
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv Nil

50%
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 082
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L110/30- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- VW 057 130 755 G
Test Oil Temperature- 40 C

EM
Engine:- AUDI 4.0 ASE
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
1 100 300 970/97
2 500 300 1100/550
3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv Nil

50%
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 084
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- VM 35022103F
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% More Than
less than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 085
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv Nil

50%
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 086
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- OPEL 97327924
Test Oil Temperature- 40 C

EM
Engine:- Z17 DTL/DTH
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 087
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200 229 004
Test Oil Temperature- 40 C

EM
Engine:- F9Q803/804
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv Nil

50%
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 088
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA 22100- ON010
Test Oil Temperature- 40 C

EM
Engine:- D- 4D 1.4
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 089
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1920 FL
FORD3M5Q 9A 543AA Test Oil Temperature- 40 C

EM
Engine:- 9HZ/9HY
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580

S
5 2000 1350 600/1200

EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 093
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- HONDA 16410RBDE000
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 096
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 8911S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 640 070 06 01
Test Oil Temperature- 40 C

EM
Engine:- OM640- 940/941/942
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580

S
5 2000 1350 600/1200

EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 099
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- RENAULT 8200409390
Test Oil Temperature- 40 C

EM
Engine:- M9R 760 2.0DCi
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 101
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- KIA/HYUNDAI
33100- 4A010 Test Oil Temperature- 40 C

EM
Engine:- D4FA / D4CB
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 102
Inlet Feed Pressure - 0.2 BAR
Type Designation:-
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- peu/for/cit/maz
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv Nil

50%
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 104
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- VM 35022098F
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv Nil

50%
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 105
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA 22100- 33040
Test Oil Temperature- 40 C

EM
Engine:- D- 4D INDTV
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% More Than
less than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 106
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA 22100- 33030
Test Oil Temperature- 40 C

EM
Engine:- D- 4D 1.4
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 112
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA 22100- 33011
Test Oil Temperature- 40 C

EM
Engine:- D- 4D 1.4
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 113
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA 22100- 0N010
Test Oil Temperature- 40 C

EM
Engine:- D- 4D 1.4
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580

S
5 2000 1350 600/1200

EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv Nil

50%
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 114
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA 22100- 33020
Test Oil Temperature- 40 C

EM
Engine:- D- 4D 1.4
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 119
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L110/30- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- VW 057 130 755h
Test Oil Temperature- 40 C

EM
Engine:- AUDI 4.2 BMC
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
1 100 300 970/97
2 500 300 1100/550
3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv Nil

50%
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 120
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 8911S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 640 070 07 01
Test Oil Temperature- 40 C

EM
Engine:- OM640- 940/941/942
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580

S
5 2000 1350 600/1200

EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 125
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R90/20- 89S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 1351 7 795714
Test Oil Temperature- 40 C

EM
Engine:- 204D4 / 306D3
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
LT
3 1000 500 800/800
4 1000 1000 Max 10% less More Than
than 3 720/720
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 800/800
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 126
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 89S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW 1351 7 795714
Test Oil Temperature- 40 C

EM
Engine:- 204D4 / 306D3
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 127
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 89S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB664 070 00 01
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 132
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 1S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1920 JE
Test Oil Temperature- 40 C

EM
Engine:- RHY 2.0 HDi
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

N

mm3st/ccmin
1 100 300 560/56
LI

2 500 300 600/300

3 1000 500 600/600
ER

4
5 1000 1000 Max 10% More Than
less than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 134
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA 22100- ON020
Test Oil Temperature- 40 C

EM
Engine:- 1.4 4- D4
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 141
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- HONDA 16790RBDE020
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% More Than
less than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 146
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 89S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- BMW
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% More Than
less than 3 580/580

S
5 2000 1350 600/1200

EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 153
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R70/20- 8911S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- DB 660 070 0101
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 162
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 16S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1920 CY
Test Oil Temperature- 40 C

EM
Engine:- PSA RHY/RHZ 2.0 HDi
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
N

1 100 300 560/56

LI

2 500 300 600/300

3 1000 500 600/600
ER

4 1000 500 Activate Aux >400/400

Button

5 1000 1000 Max 10% less More Than

than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 163
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 16S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1920 EA
Test Oil Temperature- 40 C

EM
Engine:- PSA RHY/RHS 2.0 HDi
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

mm3st/ccmin
N

1 100 300 560/56

LI

2 500 300 600/300

3 1000 500 600/600
ER

4 1000 500 Activate >400/400

Aux Button

5 1000 1000 Max 10% More Than

less than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 164
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R65/10- 1S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- PSA 1920 JE
Test Oil Temperature- 40 C

EM
Engine:- RHY 2.0 HDi
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

N

mm3st/ccmin
1 100 300 560/56
LI

2 500 300 600/300

3 1000 500 600/600
ER

4
5 1000 1000 Max 10% More Than
less than 3 540/540
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40

D
- -

LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 010 168
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L70/20- 8911S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:-
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
Set S3000 test unit to ‘PCV’

1. RUNNING IN/LEAK TEST

EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Remove one suction valve cover from fuel pump and fit T016- 702 Transfer pressure
adaptor and connect to bench pressure gauge.
LI

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

ER

Pressure BAR
1 350 250 1.5-2.0
2 1000 500 4.0-5.0
M

3 2000 1350 2.5-3.0

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin

D
1 100 300 500/50
2 500 300 640/320

LT
3 1000 500 650/650
4 1000 1000 Max 10% less More Than
than 3 580/580
5 2000 1350 600/1200

S
EM
3. RESISTANCES

Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL

ST
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

2 - 3.2-3.6 - 40
SY
- -

4. SCV Operation
EL

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
S

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

IE

Mm3st/ccmin
1 1000 NOM Pump Drv 650/650
100%
D

2 1000 NOM Pump Drv 50% Nil

N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 020 002
Inlet Feed Pressure - 1.5 BAR
Type Designation:- CR/CP1S3/R70/10- 16S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- IVECO 99483254
Test Oil Temperature- 40 C

EM
Engine:- IVECO 8140.43
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Remove Fuel Pump PCV and fit to test rail. Fit Blank T031- 3051 to Fuel Pump.
Connect Fuel Pump Cable T031- 3002 to PCV and element Shut off valve.
SY
1. RUNNING IN/LEAK TEST

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

EL

1 350 250 15 Secs No Unusual noise

2 2000 500 3 Mins No Leaks and
S

3 2000 1500 No abnormal

IE

Temperature rise.

2. FUEL DELIVERY
D

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
N

1 100 300 500/50

LI

2 500 300 640/320

3 1000 500 650/650
ER

4 1000 500 Activate Aux >420/420

Button

5 1000 1000 Max 10% less More Than

than 3 580/580
M

6 2000 1350 600/1200

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. RESISTANCES
Test Bench Speed - RPM PCV Resistance Shut off Valve INLET FUEL
 Resistance  TEMP °C

1 - 2.5-2.7 23-24 20

2 - 3.5-3.7 26-27 40
- -

D
LT
S
EM
ST
SY
S EL
IE
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 020 007
Inlet Feed Pressure - 0.2 BAR
Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- iveco
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031-3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031-3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
1 100 300 970/97
2 500 300 1100/550

3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031-3002 to fuel pump Suction Control Valve

Set test unit T031-3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv Nil

50%
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 020 015
Inlet Feed Pressure - 0.2 BAR
Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- CDC 3954343
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031-3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031-3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
1 100 300 970/97
2 500 300 1100/550

3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031-3002 to fuel pump Suction Control Valve

Set test unit T031-3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv Nil

50%
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 020 027
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L110/30- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- MITSUBISHI ME192242
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Cm/1000
1 100 300 970/97
2 500 300 1100/550
3 1000 500 1100/1100

D
4 1000 1000 Max 10% More Than
less than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv 50% Nil

D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 020 028
Inlet Feed Pressure - 0.2 BAR
Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- MITSUBISHI ME221816
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031-3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031-3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
1 100 300 970/97
2 500 300 1100/550
3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031-3002 to fuel pump Suction Control Valve

Set test unit T031-3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv Nil

50%
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 020 034
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L110/30- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- MAN 5111103716
Test Oil Temperature- 40 C

EM
Engine:- D0836
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
1 100 300 970/97
2 500 300 1100/550

3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv Nil

50%
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 020 039
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/R110/30- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- 3972815
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - R

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin

1 100 300 970/97

2 500 300 1100/550
3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv 50% Nil

D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 020 045
Inlet Feed Pressure - 0.2 BAR
Type Designation:-CR/CP3S3/L110/30-789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- CDC 3971529
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031-3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031-3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
1 100 300 970/97
2 500 300 1100/550
3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031-3002 to fuel pump Suction Control Valve

Set test unit T031-3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv 50% Nil

D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
Testing Prerequisites

LT
Pump Designation:- 0 445 020 054
Inlet Feed Pressure - 0.2 BAR
Type Designation:- CR/CP3S3/L110/30- 789S
Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- SISU 837069146
Test Oil Temperature- 40 C

EM
Engine:-
Direction of Rotation - L

ST
Remove injector pipes from test rail and blank off with T031- 3005
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031- 3002 to PCV.
SY
1. RUNNING IN/LEAK TEST
EL

Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

1 350 250 15 Secs No Unusual noise

S

2 2000 500 3 Mins No Leaks and

3 2000 1500 No abnormal
IE

Temperature rise.
D

2. Transfer Pressure
N

Test Bench Speed - RPM Rail Pressure - BAR Comments Transfer

Pressure BAR
LI

1 350 250 1.5-2.0

ER

2 1000 500 4.0-5.0

3 2000 1350 2.5-3.0
M

MERLIN S3000 COMMON RAIL TEST SYSTEM

 3. FUEL DELIVERY

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
1 100 300 970/97
2 500 300 1100/550
3 1000 500 1100/1100

D
4 1000 1000 Max 10% less More Than
than 3 950/950

LT
5 2000 1350 1000/2000

S
3. RESISTANCES

EM
Test Bench Speed - RPM SCV Resistance Temp Sender INLET FUEL
 Resistance  TEMP °C

1 - 2.8-3.2 - 20

ST
2 - 3.2-3.6 - 40
- - SY
4. SCV Operation

Connect lead T031- 3002 to fuel pump Suction Control Valve

Set test unit T031- 3000 to SCV.
EL

Test Bench Speed - RPM Rail Pressure - BAR Comments Delivery

Mm3st/ccmin
S

1 1000 NOM Pump Drv 1100/1100

100%
IE

2 1000 NOM Pump Drv Nil

50%
D
N
LI
ER
M

MERLIN S3000 COMMON RAIL TEST SYSTEM