Boschinjectortestplans 29 WEB

S3000 Common Rail
Test System
TEST DATA
D
LT
Injector Designation:- 0 445 110 002 Testing Prerequisites
Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREK10S
Test Oil Specification- ISO 4113
S
Manufacturer I.D.:- FIAT 46472233
Test Oil Temperature- 40 C
EM
Engine:- 182 B 4000 1.9 JTD
Solenoid Resistance @ 20C - 600 m
ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL
1500 1350 900 50-55 <35.0/55.0 Max Fuel

400 250 700 9.0-10.0 <20.0/9.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S
400 150-250 700 N/A - S.O.I

IE
Start of Injection (S.O.I)

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

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPS19/ZERAK10S
S
Manufacturer I.D.:- DB 611 070 05 87
EM
Engine:- OM611-961/980
ST
Remove all washers from injectors
Fit Injectors to Injector rack. Attach cables T031-3201 and metering pipes to
injectors. Close protective cover.
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 73-77 <35.0/55.0 Max Fuel
S
400 250 700 14.0-15.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.
N
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to
400RPM. Increase Rail pressure slowly until atomised fuel can just be seen emitting
LI
from nozzle holes. Rail pressure should be 150-200BAR.
Note:-
ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
0 986 435 005 Mount Suitable Test Pump
Type Designation:- CR/IPS19/ZEREAK20S
S
EM
Engine:- OM668-941
ST
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 52-57 <35.0/55.0 Max Fuel
S
400 250 700 11.0-12.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N
LI
Note:-
ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPS19/ZERAK10S Mount Suitable Test Pump
S
Manufacturer I.D.:- FIAT 46547897 Test Oil Specification- ISO 4113
EM
Engine:- 188 A 2.000 1.9JTD Test Oil Temperature- 40 C
ST
injectors.
SY
Close protective cover.
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Commen
RPM BAR cc/1000 Mm3st/ccmin ts
EL
1000 1000 1200 N/A - Purge

System
2000 1500 1200 N/A - Check for
S
Leaks
1500 1350 900 60-65 <35.0/55.0 Max Fuel
IE
400 250 700 12.0-13.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- RENAULT 7700 107 165
EM
Engine:- F9Q 1.9DCi
ST
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 64-69 <35.0/55.0 Max Fuel
S
400 250 700 9.0-10.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N
LI
Note:-
ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611-961 611-981
ST
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 65-70 <35.0/55.0 Max Fuel
S
400 250 700 13.0-14.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N
LI
Note:-
ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFS17/ZERAK10S
S
Manufacturer I.D.:- BMW 13 53 7 785 437
EM
Engine:- 30 6 D1 3.0D
ST
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 61-66 <35.0/55.0 Max Fuel
S
400 250 700 5.0-7.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N
LI
Note:-
ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 30 4 D1 2.0D
ST
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 55-60 <35.0/55.0 Max Fuel
S
400 250 700 8.0-9.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N
LI
Note:-
ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611.981 OM611.987
ST
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 71-76 <35.0/55.0 Max Fuel
S
400 250 700 12.0-13.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N
LI

ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFS17/ZEREW10S
S
Manufacturer I.D.:- PSA 96533448
EM
Engine:- PSA2.2HDi 4HX
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 62-66 <35.0/55.0 Max Fuel

IE
400 250 700 11.0-12.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
INJECTOR DATA TEST CONDITIONS
D
PART No: 0 445 110 038 (0 986 435 016) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IFS17/ZEREK10S TEST OIL: ISO 4113
LT
O.E.M. REF: RENAULT 8200 010 074 TEST OIL TEMP: 40C
ENGINE: G9T-710 SOLENOID RESISTANCE @ 20C - 600m
S
EM
Remove all washers from injectors.
Fit injectors to rack.
Fit injector pipe.
Attach injector cables T031-3003.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L
Purge System & Check for

1000 1000 700 N/A - -
Leaks
SE
1500 1350 900 76-78 <35.0 <55.0 Max Fuel
400 250 700 8-9 <20.0 <9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I
400 400 60 0.2-3.0 - - Pre Injection

N
LI
Start of Injection
ER
1) Stop test bench.

2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection.
4) Close protective cover.
M
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.
MERLIN S3000 COMMON RAIL TEST SYSTEM

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- PSA 96375360/1980-72
EM
Engine:- 2.0 HDi
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 57-60 <35.0/55.0 Max Fuel

400 250 700 10.0-11.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFS17/ZEREK10S
S
Manufacturer I.D.:- BMW 13 53 778 984
EM
Engine:- 30 6 D1
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 70-72 <35.0/55.0 Max Fuel

400 250 700 8.0-9.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFS17/ERAK10S Mount Suitable Test Pump
S
Manufacturer I.D.:- BMW 13 53 7 785 574 Test Oil Specification- ISO 4113
EM
Engine:- 25 6D1 Test Oil Temperature- 40 C
ST
SY
EL
1000 1000 1200 N/A - Purge

System
2000 1500 1200 N/A - Check for
S
Leaks
1500 1350 900 55-60 <35.0/55.0 Max Fuel
IE
400 250 700 7.0-9.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFS17/ZERAK10S Mount Suitable Test Pump
S
Manufacturer I.D.:- BMW 1353 7 785 983 Test Oil Specification- ISO 4113
EM
Engine:- Test Oil Temperature- 40 C
ST
injectors.
SY
Pump Speed Rail Pressure Pulse Width Delivery Comments

RPM BAR cc/1000
EL
1000 1000 1200 Purge System

2000 1500 1200 N/A Check for Leaks
S
1500 1350 900 53.0-57.0 Max Fuel

400 250 700 6.0-8.0 Idle
IE
1500 1350 900 <35 Max Back leakage

2000 1350 Run pump only <12.5 Max Back leakage
D
400 150-200 700 - S.O.I

N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPL19/ZERAK20S
S
EM
Engine:- OM646-951/961
ST
Fit Injectors to Injector rack. Attach cables T031-3201and metering pipes to
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 73-77 <35.0/55.0 Max Fuel

400 250 700 14.0-15.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM646-951/961
ST
Fit Injectors to Injector rack. Attach cables T031-3201and metering pipes to
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 73-77 <35.0/55.0 Max Fuel

400 250 700 14.0-15.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- PSA 1980-78
EM
Engine:- RHW 2.0HDi 16v
ST
injectors.
SY
EL
1000 1000 1200 N/A - Purge

System
2000 1500 1200 N/A - Check for

S
Leaks
1500 1350 900 55-60 <35.0/55.0 Max Fuel
IE
400 250 700 11.0-12.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- VM 1506 2036F
EM
Engine:- 2.5CRD
ST
injectors.
SY
EL
1000 1000 1200 N/A - Purge

System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 80-83 <35.0/55.0 Max Fuel

IE
400 250 700 11.5-12.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
Remove Fuel Connection T016-3052 Close Protective cover. Run Test Bench to
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- PSA 2.0HDi RHY
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 60-64 <35.0/55.0 Max Fuel

400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- RENAULT 8200010075
EM
Engine:- 1.9 DCi Solenoid Resistance @ 20C - 600 m
ST
injectors.
SY
Pump Speed Rail Pressure Pulse Width Delivery Comments
RPM BAR cc/1000
EL
1000 1000 1200 Purge System

2000 1500 1200 N/A Check for Leaks
1500 1350 900 55-60 Max Fuel
S
400 250 700 10.0-12.0 Idle

IE
1500 1350 900 <35 Max Back leakage

2000 1350 Run pump only <12.5 Max Back leakage
D
400 150-200 700 0.01-0.1 S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- HYUNDAI 33800-27000
EM
Engine:- D3EA/D4EA
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 65-68 <35.0/55.0 Max Fuel

400 250 700 10.0-12.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 182 B 9.000/ 186 A 6.000 1.9JTD
ST
injectors.
SY
EL
1000 1000 1200 N/A - Purge

System
2000 1500 1200 N/A - Check for

S
Leaks
1500 1350 900 77-80 <35.0/55.0 Max Fuel
IE
400 250 700 10.0-11.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611-981/OM611-987
ST
SY
EL
1000 1000 1200 N/A - Purge

System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 72-75 <35.0/55.0 Max Fuel

IE
400 250 700 14.0-15.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- 611 070 08 07
EM
Engine:- OM611.981 / 987
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 72-75 <35.0/55.0 Max Fuel

400 250 700 14.0-15.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611-962
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 64-68 <35.0/55.0 Max Fuel

400 250 700 12.0-13.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPL20/ZEREAK20S
S
EM
Engine:- 8HX / 8HZ
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 43-47 <35.0/55.0 Max Fuel

400 250 700 10.0-11.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- PSA2.0HDi RHS/RHY
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 60-64 <35.0/55.0 Max Fuel

400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- VOLVO 8658350
EM
Engine:- D5244T
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 69-71 <35.0/55.0 Max Fuel

IE
400 250 700 9.0-10.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFL17/ZEREAK20S
S
EM
Engine:- 20 4 D4 / 30 6 D2
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 80-84 <35.0/55.0 Max Fuel

400 250 700 14.5-15.5 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:-
S
Manufacturer I.D.:-
EM
Engine:-
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 84.0-87.0 <35.0/55.0 Max Fuel

IE
400 250 700 8.0-10.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA

PART No: 0 445 110 083 TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL17/ZERAK10S TEST OIL: ISO 4113
O.E.M. REF: FIAT 55184536 TEST OIL TEMP: 40C
ENGINE: 1.3JTD, OPEL 1.3CDTI SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 65-70 <35.0 <55.0 Max Fuel
400 250 700 7-9 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
400 400 60 0.1-3.0 - - Pre Injection
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFL19/ZERAK10S
S
EM
Engine:- REN 2.2 DCi 110KW G9T-742
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 68-73 <35.0/55.0 Max Fuel

IE
400 250 700 11.5-12.5 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- REN 1.9 DCi OPEL 1.9 DTi
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 77-80 <35.0/55.0 Max Fuel

IE
400 250 700 11.0-12.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM668-914
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 56-60 <35.0/55.0 Max Fuel

400 250 700 14.0-15.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- HYUNDAI 33800-4A000
EM
Engine:- D4CB 2.5CRDI
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 78-84 <35.0/55.0 Max Fuel

IE
400 250 700 5.5-7.5 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM628-962
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 67-71 <35.0/55.0 Max Fuel

400 250 700 11.0-12.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611-981 / OM611-987
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 75-78 <35.0/55.0 Max Fuel

400 250 700 9.0-10.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- OM612.965
EM
Engine:- MB
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 70-75 <35.0/55.0 Max Fuel

IE
400 250 700 10.0-12.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- OM612.965
EM
Engine:- MB
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 70-75 <35.0/55.0 Max Fuel

IE
400 250 700 10.0-12.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611-962
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 67-72 <35.0/55.0 Max Fuel

400 250 700 11.0-12.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPL17/ERAK10S
S
Manufacturer I.D.:- HYUNDAI 33800-27000
EM
Engine:- D3EA/D4EA
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 67-72 <35.0/55.0 Max Fuel

400 250 700 10.5-11.5 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFS19/ERAK10S
S
EM
Engine:- G9T-722 / G9T-750 2.2DCi
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 57-62 <35.0/55.0 Max Fuel

IE
400 250 700 10.0-11.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611-981 OM644-987
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 73-77 <35.0/55.0 Max Fuel

400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611-981 OM644-987
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 73-77 <35.0/55.0 Max Fuel

400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 1.9 DCi
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 64-67 <35.0/55.0 Max Fuel

400 250 700 10.0-11.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- Fiat 55192534
EM
Engine:- 192 B / 537 A
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 85-90 <35.0/55.0 Max Fuel

400 250 700 9.0-10.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 1.9JTD 8V
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 85-90 <35.0/55.0 Max Fuel

IE
400 250 700 8.5-9.5 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- VW 057130276H
EM
Engine:- AKF3.3TDi
ST
SY
EL
1000 1000 1200 N/A - Purge

System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 62-67 <35.0/55.0 Max Fuel

IE
400 250 700 10.0-11.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM668-940
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 56-60 <35.0/55.0 Max Fuel

400 250 700 10.0-12.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPL17/ERAK20S
S
Manufacturer I.D.:- OPEL 97300091
EM
Engine:- Z17DTL
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 50-55 <35.0/55.0 Max Fuel

IE
400 250 700 15.0-16.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 1.9JTD 8V
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 80-85 <35.0/55.0 Max Fuel

IE
400 250 700 10.0-11.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611-962 / OM612-962
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 70-72 <35.0/55.0 Max Fuel

400 250 700 9.0-10.0 <20.0/9.0 Idle
IE
400 150-250 700 N/A - S.O.I

D
N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- MWM 94 070 46 4 0024
EM
Engine:-
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 80-85 <35.0/55.0 Max Fuel

IE
400 250 700 9.0-10.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFS17/ZEREK10S
S
EM
Engine:-
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 52.5-57.5 <35.0/55.0 Max Fuel

400 250 700 9.0-10.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA

TYPE: CR/IPS17/ZEREK10S TEST OIL: ISO 4113
EXCHANGE: 0 986 435 084 TEST OIL TEMP: 40C
O.E.M. REF: BMW 13 53 7 787 234 SOLENOID RESISTANCE @ 20C - 600m
ENGINE: 30 6 D2 3.0d 110/150/160 KW

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A
- - Leaks
1500 1350 900 83-88 <35.0 55.0 Max Fuel
400 250 700 12-16 <20.0 9.0 Idle
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
3) Remove fuel connection T031-3052.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 1.4HDi 8HX/8HZ
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 41-45 <35.0/55.0 Max Fuel

IE
400 250 700 11.0-12.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
LI

ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFL17/ZEREK20S
S
Manufacturer I.D.:- FORD 3M5Q 9F593 CA
EM
Engine:- 1.6 TDCI
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 47-50 <35.0/55.0 Max Fuel

IE
400 250 700 5.0-6.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
Injector Designation:- 0 445 110 139/140 Testing Prerequisites
S
EM
Engine:- OM646-982
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 81-86 <35.0/55.0 Max Fuel

400 250 700 11.5-12.5 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- G9U-724 / G9U-754 2.5DCi
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 92-95 <35.0/55.0 Max Fuel

IE
400 250 700 10.0-11.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- F9Q 820
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 64-69 <35.0/55.0 Max Fuel

400 250 700 9.0-10.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 20 4 D 4 1.8D
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 55-60 <35.0/55.0 Max Fuel

IE
400 250 700 5.0-7.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
PART No: 0 445 110 156 (155) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPS19/ZERES20S TEST OIL: ISO 4113
LT
O.E.M. REF: MERCEDES BENZ TEST OIL TEMP: 40C
ENGINE: OM646.951/961 + VARIOUS SOLENOID RESISTANCE @ 20C - 600m
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A - -
Leaks
SE
1500 1350 900 70-75 <35.0 <55.0 Max Fuel
400 250 700 8-10 <20.0 <9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- VW 057 130 277 L
EM
Engine:- ASE 4.0 TDI
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 75.0-80.0 <35.0/55.0 Max Fuel

IE
400 250 700 8.0-10.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- Z19 DTH
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 95-99 <35.0/55.0 Max Fuel

IE
400 250 700 8.0-9.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
TYPE: CR/IFL17/ZEREA20S TEST OIL: ISO 4113
LT
O.E.M. REF: BMW SOLENOID RESISTANCE @ 20C - 600m
S
ENGINE: 204D4, 306D2
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 97-103 <35.0 55.0 Max Fuel
400 250 700 4-7 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA

PART No: 0 445 110 165 (0 986 435 103) TEST PUMP: SUITABLE CR PUMP
TYPE: CR/IPL19/ZEREK20S TEST OIL: ISO 4113
O.E.M. REF: VAUXHALL/OPEL TEST OIL TEMP: 40C
ENGINE: 1.9 CDTI SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 87-93 <35.0 <55.0 Max Fuel
400 250 700 8-12 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

PART No: 0 445 110 166-167 TEST PUMP: SUITABLE CR PUMP
ENGINE: A160, A180, A200 CDI SOLENOID RESISTANCE @ 20C - 600m
B180, B200 CDI

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 62-68 <35.0 <55.0 Max Fuel
400 250 700 7-11 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPL17/ZEREK20S
S
Manufacturer I.D.:- NISSAN 16600 DB 000
EM
Engine:- 1.6 HDi -
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 95-100 <35.0/55.0 Max Fuel

IE
400 250 700 6.0-7.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
EXCHANGE: - TEST OIL TEMP: 40C
O.E.M. REF: RENAULT 3.0L SOLENOID RESISTANCE @ 20C - 600m
S
ENGINE: -
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 112-118 <35.0 55.0 Max Fuel
400 250 700 6-9 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
TYPE: CR/IPL21/ZERES20S TEST OIL: ISO 4113
LT
O.E.M. REF: OPEL TEST OIL TEMP: 40C
ENGINE: 1.7 CDTi SOLENOID RESISTANCE @ 20C - 600m
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A - -
Leaks
SE
1500 1350 900 54-60 <35.0 <55.0 Max Fuel
400 250 700 9-11 <20.0 <9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPl17/ZEREK20S
S
Manufacturer I.D.:- OPEL 897 363 812
EM
Engine:- OM648
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
S
1500 1350 900 58-64 <35.0/55.0 Max Fuel

400 250 700 10.0-11.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM648
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 64-70 <35.0/55.0 Max Fuel

400 250 700 10.0-12.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA

TYPE: CR/IPS19/ZEREAK10S TEST OIL: ISO 4113
O.E.M. REF: MERCEDES SPRINTER/VITO TEST OIL TEMP: 40C
ENGINE: 2.2/2.7L SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 64-68 <35.0 <55.0 Max Fuel
400 250 700 10-12 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- Z13 DTH
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 68-72 <35.0/55.0 Max Fuel

IE
400 250 700 7.0-9.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- HYUNDAI 33800 4A100
EM
Engine:- D4CB 2.5Lt
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 88.0-93.0 <35.0/55.0 Max Fuel

IE
400 250 700 8.0-10-0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 1.3JTD 8V
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 80-85 <35.0/55.0 Max Fuel

IE
400 250 700 7-9 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- PSA 1980-H3
EM
Engine:- 1.6 HDi - FORD 1.6 TDCi
ST
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 52-55 <35.0/55.0 Max Fuel
S
400 250 700 8.0-9.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- OM611-981 OM644-987
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 73-77 <35.0/55.0 Max Fuel

400 250 700 13.0-14.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- 647 070 00 87
EM
Engine:- OM646.982
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 73-76 <35.0/55.0 Max Fuel

400 250 700 12.0-13.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA

TYPE: CR/IPL19/ZEREAK10S TEST OIL: ISO 4113
ENGINE: A SERIES, A160/170 CDI SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 57-63 <35.0 <55.0 Max Fuel
400 250 700 8-12 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
PART No: 0 445 110 201 / 202 TEST PUMP: SUITABLE CR PUMP
LT
ENGINE: 2.2L SOLENOID RESISTANCE @ 20C - 600m
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 68-72 <35.0 55.0 Max Fuel
400 250 700 8-10 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:-
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 68-74 <35.0/55.0 Max Fuel

IE
400 250 700 8.0-9.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA

TYPE: CR/IFL17/ZEREAK20S TEST OIL: ISO 4113
O.E.M. REF: BMW TEST OIL TEMP: 40C
ENGINE: 118d, 318d 2.0L SOLENOID RESISTANCE @ 20C - 600m
325d, 525d 3.0L

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 80-86 <35.0 <55.0 Max Fuel
400 250 700 9-13 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: BMW 5 SERIES TEST OIL TEMP: 40C
05/2004>03/2007 SOLENOID RESISTANCE @ 20C - 600m
ENGINE: 2.5L

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 83-88 <35.0 <55.0 Max Fuel
400 250 700 7-10 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: FIAT 55192740 SOLENOID RESISTANCE @ 20C - 600m
S
ENGINE: 939 A 3000 2.4JTD 20V
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 108-113 <35.0 55.0 Max Fuel
400 250 700 5-8 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: 23670-33030 SOLENOID RESISTANCE @ 20C - 600m
S
ENGINE: TOYOTA
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 44-48 <35.0 55.0 Max Fuel
400 250 700 4-6 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- BMW 13 53 7793836
EM
Engine:- 30 6 D2 / 20 4 D4
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 80-85 <35.0/55.0 Max Fuel

400 250 700 8.0-9.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: RENAULT/SUZUKI TEST OIL TEMP: 40C
ENGINE: 1.9L, F9Q SOLENOID RESISTANCE @ 20C - 600m
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 72-77 <35.0 55.0 Max Fuel
400 250 700 6-9 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA

0 986 435 145 TEST OIL: ISO 4113
TYPE: CR/IPL19/ZEREK20S TEST OIL TEMP: 40C
O.E.M. REF: HONDA SOLENOID RESISTANCE @ 20C - 600m
ENGINE: 2.2 CDTI

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 60-68 <35.0 <55.0 Max Fuel
400 250 700 10-14 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

PART No: 0 445 110 237/238 TEST PUMP: SUITABLE CR PUMP
O.E.M. REF: DB 646 070 07 87 TEST OIL TEMP: 40C
ENGINE: OM646-966 SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A
- - Leaks
1500 1350 900 100-110 <35.0 55.0 Max Fuel
400 250 700 12-16 <20.0 9.0 Idle
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- PSA 1980 H2
EM
Engine:- 9HX 1.6 HDi
ST
SY
1000 1000 1200 N/A - Purge

EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 47-50 <35.0/55.0 Max Fuel

IE
400 250 700 9.0-1.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- FIAT/OPEL 55198218
EM
Engine:- 1.9 CDTI 150 HP
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 95-100 <35.0/55.0 Max Fuel

400 250 700 7.0-9.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA

TYPE: CR/IPL21/ZERES20S TEST OIL: ISO 4113
O.E.M. REF: IVECO 504088823 TEST OIL TEMP: 40C
ENGINE: - SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 107-112 <35.0 <55.0 Max Fuel
400 250 700 6-8 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
400 400 60 0.2-3.0 - - Pre Injection
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: FORD RANGER/MAZDZA 4x4 TEST OIL TEMP: 40C
ENGINE: 2.5L TURBO SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A
- - Leaks
1500 1350 900 62-67 <35.0 55.0 Max Fuel
400 250 700 6-9 <20.0 9.0 Idle
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
TYPE: CR/IPL21/ZEREZ20S TEST OIL: ISO 4113
LT
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A - -
Leaks
SE
1500 1350 900 77-82 <35.0 <55.0 Max Fuel
400 250 700 8-10 <20.0 <9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I
- - - - - - Pre Injection
N
LI
Start of Injection
ER
1) Stop test bench.

M
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: PEUGEOT/CITROEN TEST OIL TEMP: 40C
ENGINE: 1.4HDI SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 64-71 <35.0 <55.0 Max Fuel
400 250 700 6-10 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
- - - - - - -
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: HYUNDAI / KIA TEST OIL TEMP: 40C

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 98-102 <35.0 <55.0 Max Fuel
400 250 700 8-11 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 182 B 4000 1.9 JTD
ST
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 50-55 <35.0/55.0 Max Fuel
S
400 250 700 9.0-10.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: TOYOTA TEST OIL TEMP: 40C
ENGINE: 1.4 D4D SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 42-48 <35.0 <55.0 Max Fuel
400 250 700 5-9 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: MERCEDES-BENZ VITO, VIANO TEST OIL TEMP: 40C

Fit injector pipe.
Attach injector cables T031-3201

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 81-86 <35.0 <55.0 Max Fuel
400 250 700 11.5-12.5 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- NISSAN
EM
Engine:- 2.5
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 95-100 <35.0/55.0 Max Fuel

400 250 700 10.5-12.5 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- BMW 13 53 7785 94
EM
Engine:- 30 6 D1
ST
SY
1000 1000 1200 N/A - Purge
System
EL
2000 1500 1200 N/A - Check for

Leaks
1500 1350 900 69-72 <35.0/55.0 Max Fuel
S
400 250 700 8.0-9.0 <20.0/9.0 Idle

IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N
LI
Note:-
ER
M
S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: VAUXHALL/OPEL/CHEVROLET TEST OIL TEMP: 40C
ENGINE: 2.0 CDTI / CDRI SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 97-105 <35.0 <55.0 Max Fuel
400 250 700 5-7 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:-IVECO 5040887755
EM
Engine:- FIAE 0481F Daily 2.3
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for

Leaks
S
1500 1350 900 83-90 <35.0/55.0 Max Fuel

IE
400 250 700 6.0-7.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: HYUNDAI/KIA TEST OIL TEMP: 40C
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A - -
Leaks
SE
1500 1350 900 108-112 <35.0 <55.0 Max Fuel
400 250 700 8-10 <20.0 <9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 939.A.7000 1.9JTD
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 90-95 <35.0/55.0 Max Fuel

IE
400 250 700 10.0-11.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- HYUNDAI 33800 4A100
EM
Engine:- D4CB 2.5Lt
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 62-67 <35.0/55.0 Max Fuel

IE
400 250 700 5.0-7.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:-
ST
SY
EL
1000 1000 1200 N/A - Purge

System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 100-110 <35.0/55.0 Max Fuel

IE
400 250 700 9.0-10.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: - SOLENOID RESISTANCE @ 20C - 600m
S
ENGINE: -
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 76-80 <35.0 55.0 Max Fuel
400 250 700 9-11 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: BMW116/8D, 316/8D, X1, MINI TEST OIL TEMP: 40C

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 86-92 <35.0 <55.0 Max Fuel
400 250 700 12-16 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
PART No: 0 445 110 290 (WAS 126) TEST PUMP: SUITABLE CR PUMP
LT
O.E.M. REF: HYUNDAI / KIA TEST OIL TEMP: 40C
ENGINE: 2.0 CRDi SOLENOID RESISTANCE @ 20C - 600m
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A - -
Leaks
SE
1500 1350 900 69-75 <35.0 <55.0 Max Fuel
400 250 700 5-8 <20.0 <9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:-RENAULT 8200606383
EM
Engine:-
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for

Leaks
S
1500 1350 900 58-62 <35.0/55.0 Max Fuel

IE
400 250 700 8.0-10.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
TYPE: CR/IFL17/ZEREK20S TEST OIL: ISO 4113
LT
O.E.M. REF: PEUGEOT/CITROEN SOLENOID RESISTANCE @ 20C - 600m
S
ENGINE: 1.6 HDi
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 68-72 <35.0 55.0 Max Fuel
400 250 700 6-8 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: VOLVO V70, V80, TEST OIL TEMP: 40C

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 108-116 <35.0 <55.0 Max Fuel
400 250 700 8-10 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: ALFA/FIAT/LANCIA TEST OIL TEMP: 40C
ENGINE: 2.0L JTD SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 95-100 <35.0 <55.0 Max Fuel
400 250 700 6-9 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: ALFA ROMEO, FIAT, LANCIA TEST OIL TEMP: 40C
ENGINE: 1.6 JTD SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 87-93 <35.0 <55.0 Max Fuel
400 250 700 8-10 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:- 939 A 9000 2.4 JTD 20v
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for

Leaks
S
1500 1350 900 105-110 <35.0/55.0 Max Fuel

IE
400 250 700 8.0-10.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:-
S
Manufacturer I.D.:-
EM
Engine:-
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 73.0-77.0 <35.0/55.0 Max Fuel

IE
400 250 700 8.0-9.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: HYUNDAI 1.4 & 1.6/KIA 1.6 TEST OIL TEMP: 40C
ENGINE: 1.4CRDI/1.6CRDI SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.
Attach injector cables T031-3003

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 80-88 <35.0 <55.0 Max Fuel
400 250 700 6-10 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: VAUXHALL/OPEL TEST OIL TEMP: 40C

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 117-122 <35.0 <55.0 Max Fuel
400 250 700 6-8 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
TYPE: CRI 2.2 TEST OIL: ISO 4113
LT
O.E.M. REF: RENAULT TEST OIL TEMP: 40C
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A - -
Leaks
SE
1500 1350 900 105-110 <35.0 <55.0 Max Fuel
400 250 700 4-7 <20.0 <9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I
400 400 60 0.2-3.5 - - Pre Injection

N
LI
Start of Injection
ER
1) Stop test bench.

M
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: FORD, CITROEN, PEUGEOT TEST OIL TEMP: 40C
ENGINE: 1.6 TDCI, 1.6 HDI SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A
- - Leaks
1500 1350 900 75-82 <35.0 55.0 Max Fuel
400 250 700 6-10 <20.0 9.0 Idle
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: FORD KA, FIAT PUNTO, LANCIA, TEST OIL TEMP: 40C
ALFA ROMEO MITO SOLENOID RESISTANCE @ 20C - 600m
ENGINE: 1.3 TDCI, 1.3 JTD, 1.3 MULTIJET

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 80-86 <35.0 <55.0 Max Fuel
400 250 700 9-13 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: FORD FOCUS TEST OIL TEMP: 40C
ENGINE: 1.6 TDCI 12/07>12/11 SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 71-77 <35.0 <55.0 Max Fuel
400 250 700 7-11 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: AUDI/VW/SEAT/SKODA TEST OIL TEMP: 40C
ENGINE: 2.0L TDI SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipe.

Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 92-97 <35.0 <55.0 Max Fuel
400 250 700 11-14 <20.0 <9.0 Idle
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
TYPE: - TEST OIL: ISO 4113
LT
O.E.M. REF: - TEST OIL TEMP: 40C
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A - -
Leaks
SE
1500 1350 900 104-109 <35.0 <55.0 Max Fuel
400 250 700 6-8 <20.0 <9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I
400 400 60 0.2-4.0 - - Pre Injection

N
LI
Start of Injection
ER
1) Stop test bench.

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Fit injector pipe.
ST
SY
Pulse
Width
L

1000 1000 700 N/A - -
Leaks
SE
1500 1350 900 78-83 <35.0 <55.0 Max Fuel
400 250 700 10-12 <20.0 <9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I
400 400 40 0.2-4.0 - - Pre Injection

N
LI
Start of Injection
ER
1) Stop test bench.

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
ENGINE: M9R CAPACITANCE: 2.1-3.1 Uf @ 20C
S
EM
Fit injector pipe.
Attach injector cables.(T031-3003R)
Attach Bosch return pipe (0 986 612 922).

Switch S3000 to Piezo.
ST
SY
NB:- IT IS ESSENTIAL THAT PIEZO INJECTORS HAVE A CAPACITANCE TEST CARRIED
OUT BEFORE CONNECTING TO S3000 AS SEVERE DAMAGE COULD OCCUR TO THE
ELECTRONICS IF FAULTY INJECTORS ARE TRIGGERED.
L
SE
Pump Rail
Pulse Delivery Max Back Leak
Speed Pressure Comments
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
IE
- - Check for Leaks

1000 1450 1200 105-115 <40.0 60.0 Max Fuel
D
1000 1450 900 72-82 Mid Range

1000 1450 700 52-62 - - Low Speed
1000 500 700 20-25 Idle
N
400 150-250 700 N/A S.O.I

LI
ER
Start of Injection
Remove Fuel Connection T031-3052. Close Protective cover. Run Test Bench to 400RPM.
M
Increase Rail pressure slowly until atomised fuel can just be seen emitting from nozzle holes.
Rail pressure should be 150-200BAR.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: PSA TEST OIL TEMP: 40C
ENGINE: 2.2L CAPACITANCE: 2.1-3.1 Uf @ 20C
S
EM
Fit injector pipe.
Attach injector cables (T031-3003R).

ST
SY
L
SE
Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
IE
- - Check for Leaks

1000 1450 1200 107-117 <40.0 60.0 Max Fuel
D
1000 1450 900 75-84 Mid Range

1000 1450 700 54-60 - - Low Speed
1000 500 700 20-25 Idle
N
400 150-250 700 N/A S.O.I

LI
ER
Start of Injection
M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: VW TEST OIL TEMP: 40C
S
EM
Fit injector pipe.

ST
SY
L
SE
Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
IE
- - Check for Leaks

1000 1450 1200 112-116 <40.0 60.0 Max Fuel
D
1000 1450 900 78-82 Mid Range

1000 1450 700 54-60 - - Low Speed
1000 500 700 22-24 Idle
N
400 150-250 700 N/A S.O.I

LI
ER
Start of Injection
M
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: L/ ROVER FREELANDER 2 TD4 TEST OIL TEMP: 40C

Fit injector pipe.

Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 98-108 <40.0 60.0 Max Fuel
1000 1450 900 80-86 Mid Range

1000 1450 700 56-63 - - Low Speed
1000 500 700 15-20 Idle

400 150-250 700 N/A S.O.I
Start of Injection
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: CHRYSLER/JEEP/MERCEDES TEST OIL TEMP: 40C

Fit injector pipe.

Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 107-117 <40.0 60.0 Max Fuel
1000 1450 900 75-84 Mid Range
1000 1450 700 54-60 - - Low Speed
1000 500 700 22-27 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Note:-

S3000 Common Rail
Test System
TEST DATA

PART No: 0 445 115 068 (069,032,033) TEST PUMP: SUITABLE CR PUMP
O.E.M. REF: MERCEDES SPRINTER VITO TEST OIL TEMP: 40C

Fit injector pipe.

Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 100-110 <40.0 60.0 Max Fuel
1000 1450 900 65-75 Mid Range
1000 1450 700 45-55 - - Low Speed
1000 500 700 20-25 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Note:-

S3000 Common Rail
Test System
TEST DATA
D
TYPE: - TEST OIL: ISO 4113
LT
O.E.M. REF: BMW 3.0 TEST OIL TEMP: 40C
S
EM
Fit injector pipe.

ST
SY
L
SE
Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
IE
- - Check for Leaks

1000 1450 1200 110-120 <40.0 60.0 Max Fuel
D
1000 1450 900 75-85 Mid Range

1000 1450 700 55-65 - - Low Speed
1000 500 700 22-27 Idle
N
400 150-250 700 N/A S.O.I

LI
ER
Start of Injection
M
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: AUDI A8, VW TEST OIL TEMP: 40C
ENGINE: 3.0 TDI V6 CAPACITANCE: 2.1-3.1 Uf @ 20C

Fit injector pipe.

Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 117-123 <40.0 60.0 Max Fuel
1000 1450 900 78-82 Mid Range

1000 1450 700 58-62 - - Low Speed
1000 500 700 24-28 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: BMW 120D, 320D, 520D, X3 TEST OIL TEMP: 40C
ENGINE: 2.0 L CAPACITANCE: 2.1-3.1 Uf @ 20C

Fit injector pipe.

Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 165-175 <40.0 60.0 Max Fuel
1000 1450 900 78-88 Mid Range
1000 1450 700 57-63 - - Low Speed

1000 500 700 17-23 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: AUDI/VW TEST OIL TEMP: 40C
ENGINE: 2.7TDI, 3.0TDI CAPACITANCE: 2.1-3.1 Uf @ 20C

Fit injector pipe.

Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 115-125 <40.0 60.0 Max Fuel
1000 1450 900 83-93 Mid Range
1000 1450 700 60-68 - - Low Speed
1000 500 700 12-17 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: AUDI/SEAT/SKODA/VW TEST OIL TEMP: 40C
ENGINE: 2.0 TDI CAPACITANCE: 2.1-3.1 Uf @ 20C

Fit injector pipe.

Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 103-112 <40.0 60.0 Max Fuel
1000 1450 900 77-84 Mid Range
1000 1450 700 57-63 - - Low Speed

1000 500 700 15-24 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Note:-

S3000 Common Rail
Test System
TEST DATA

TYPE: CR13-18, (019 = CR13.2) TEST OIL: ISO 4113
O.E.M. REF: FIAT DUCATO/IVECO DAILY TEST OIL TEMP: 40C
ENGINE: 3.0L / 2.3-3.0L CAPACITANCE: 2.1-3.1 Uf @ 20C

Fit injector pipe.

Pump Rail
Width cc/1000
RPM BAR
cc/1000 cc/min
Purge System &
1000 1000 700 N/A
- - Check for Leaks
1000 1450 1200 105-115 <40.0 60.0 Max Fuel
1000 1450 900 68-76 Mid Range
1000 1450 700 45-53 - - Low Speed
1000 500 700 18-23 Idle
400 150-250 700 N/A S.O.I
Start of Injection
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPS21/ZIREK10S
S
Manufacturer I.D.:- IVECO 500313105
EM
Engine:- 8140-43
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 92-97 <35.0/55.0 Max Fuel

IE
400 250 700 16.0-19.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IPL32ZIRIS10S
S
Manufacturer I.D.:- RVI 50 10 412 093
EM
Engine:- 420DCi 303 Kw >2001
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 150-165 <35.0/55.0 Max Fuel

IE
400 250 700 25.0-28.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
TYPE: CR/IFS26/ZIRIS10S TEST OIL: ISO 4113
LT
O.E.M. REF: CDC 4897271 TEST OIL TEMP: 40C
S
EM
Fit injector pipes.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 82-87 <35.0 55.0 Max Fuel
400 250 700 12-18 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA

ENGINE: F1AE-0481 SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipes.

Pulse
Width

1000 1000 700 N/A
- - Leaks
1500 1350 900 70-75 <35.0 55.0 Max Fuel
400 250 700 13-15 <20.0 9.0 Idle
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:-
S
Manufacturer I.D.:-
EM
Engine:- ISB
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 115-125 <35.0/55.0 Max Fuel

IE
400 250 700 12.0-13.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFL26/ZIRIS10S
S
EM
Engine:- CSC ISB
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for

Leaks
S
1500 1350 900 100-110 <35.0/55.0 Max Fuel

400 250 700 12.0-14.0 <20.0/9.0 Idle
IE

400 150-250 700 N/A - S.O.I
D
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:-
S
Manufacturer I.D.:-
EM
Engine:- QSB
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 155-167 <35.0/55.0 Max Fuel

IE
400 250 700 5.0-7.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: IVECO DAILY TEST OIL TEMP: 40C
ENGINE: 3.0 L SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipes.

Pulse
Width

1000 1000 700 N/A
- - Leaks
1500 1350 900 82-87 <35.0 55.0 Max Fuel
400 250 700 8-12 <20.0 9.0 Idle
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
TYPE: CR/IPL26/ZIRIS10S TEST OIL: ISO 4113
LT
S
EM
Fit injector pipes.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 100-110 <35.0 55.0 Max Fuel
400 250 700 8-12 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFl26/ZIRIS20S
S
EM
Engine:- QSB
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for

Leaks
S
1500 1350 900 100-110 <35.0/55.0 Max Fuel

IE
400 250 700 13.0-15.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:- CR/IFS26/ZIRIS20S
S
EM
Engine:- QSB
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 100-110 <35.0/55.0 Max Fuel

IE
400 250 700 15.0-17.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I

N
Start of Injection
LI
ER
Note:-
M

S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: RENAULT TEST OIL TEMP: 40C
S
EM
Fit injector pipes.
ST
SY
Pulse
Width
L

1000 1000 700 N/A
- - Leaks
SE
1500 1350 900 95-100 <35.0 55.0 Max Fuel
400 250 700 12-14 <20.0 9.0 Idle

IE
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
D
400 150-250 700 N/A - - S.O.I

N
Start of Injection
LI
1) Stop test bench.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA

TYPE: CR/IFL19/ZEREK30S TEST OIL: ISO 4113
O.E.M. REF: MITSUBISHI TEST OIL TEMP: 40C

Fit injector pipes.

Pulse
Width

1000 1000 700 N/A
- - Leaks
1500 1350 900 68-72 <35.0 55.0 Max Fuel
400 250 700 12-16 <20.0 9.0 Idle
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: MAN TEST OIL TEMP: 40C
ENGINE: 4.6, 6.9 L SOLENOID RESISTANCE @ 20C - 600m

Fit injector pipes.

Pulse
Width

1000 1000 700 N/A
- - Leaks
1500 1350 900 118-125 <35.0 55.0 Max Fuel
400 250 700 22-26 <20.0 9.0 Idle
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
Type Designation:-
S
Manufacturer I.D.:-
EM
Engine:- ISB
ST
SY
1000 1000 1200 N/A - Purge
EL
System
2000 1500 1200 N/A - Check for
Leaks
S
1500 1350 900 75.0-80.0 <35.0/55.0 Max Fuel

IE
400 250 700 10.0-13.0 <20.0/9.0 Idle

D
400 150-250 700 N/A - S.O.I
Start of Injection
N

LI
ER
Note:-
M
S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: MAN TRUCK TEST OIL TEMP: 40C

Fit injector pipes.

Pulse
Width

1000 1000 700 N/A
- - Leaks
1500 1350 900 178-188 <35.0 55.0 Max Fuel
400 250 700 12-16 <20.0 9.0 Idle
Run pump
2000 1350 N/A <12.5 25.0 Seat Test
only
400 150-250 700 N/A - - S.O.I
Start of Injection
1) Stop test bench.
Note:-

Boschinjectortestplans 29 WEB

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Boschinjectortestplans 29 WEB

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Available Formats

S3000 Common Rail

1500 1350 900 50-55 <35.0/55.0 Max Fuel

400 150-250 700 N/A - S.O.I

Start of Injection (S.O.I)

rates are matched through the set.

2000 1500 1200 N/A - Check for

400 250 700 14.0-15.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test

from nozzle holes. Rail pressure should be 150-200BAR.

2000 1500 1200 N/A - Check for

400 250 700 11.0-12.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test

from nozzle holes. Rail pressure should be 150-200BAR.

Type Designation:- CR/IPS19/ZERAK10S Mount Suitable Test Pump

1000 1000 1200 N/A - Purge

400 250 700 12.0-13.0 <20.0/9.0 Idle

400 150-250 700 N/A - S.O.I

2000 1500 1200 N/A - Check for

400 250 700 9.0-10.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test

from nozzle holes. Rail pressure should be 150-200BAR.

2000 1500 1200 N/A - Check for

400 250 700 13.0-14.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test

from nozzle holes. Rail pressure should be 150-200BAR.

2000 1500 1200 N/A - Check for

400 250 700 5.0-7.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test

from nozzle holes. Rail pressure should be 150-200BAR.

2000 1500 1200 N/A - Check for

400 250 700 8.0-9.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test

from nozzle holes. Rail pressure should be 150-200BAR.

2000 1500 1200 N/A - Check for

400 250 700 12.0-13.0 <20.0/9.0 Idle

2000 1350 Run pump only N/A <12-5/25.0 Seat test

from nozzle holes. Rail pressure should be 150-200BAR.

1500 1350 900 62-66 <35.0/55.0 Max Fuel

400 250 700 11.0-12.0 <20.0/9.0 Idle

400 150-250 700 N/A - S.O.I

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.

INJECTOR DATA TEST CONDITIONS

Purge System & Check for

1500 1350 900 76-78 <35.0 <55.0 Max Fuel

400 250 700 8-9 <20.0 <9.0 Idle

400 150-250 700 N/A - - S.O.I

400 400 60 0.2-3.0 - - Pre Injection

1) Stop test bench.

MERLIN S3000 COMMON RAIL TEST SYSTEM

1500 1350 900 57-60 <35.0/55.0 Max Fuel

2000 1350 Run pump only N/A <12-5/25.0 Seat test

1500 1350 900 70-72 <35.0/55.0 Max Fuel

2000 1350 Run pump only N/A <12-5/25.0 Seat test

Stop Test Bench. Reduce Rail Pressure on S3000 to Zero.

Type Designation:- CR/IFS17/ERAK10S Mount Suitable Test Pump

Solenoid Resistance @ 20C - 600 m

1000 1000 1200 N/A - Purge

400 250 700 7.0-9.0 <20.0/9.0 Idle

400 150-250 700 N/A - S.O.I

Type Designation:- CR/IFS17/ZERAK10S Mount Suitable Test Pump

Pump Speed Rail Pressure Pulse Width Delivery Comments

1000 1000 1200 Purge System