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    DJAMel L
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    1. A common rail fuel pump was tested on a Merlin S3000 test system. Leak and transfer pressure tests were performed within expected parameters. 2. Pump efficiency and fuel delivery tests showed delivery rates above expected minimums across a range of rail pressures and pump drive percentages. 3. Resistance checks for the pressure control valve and suction control valve were within expected ranges under different temperature conditions.

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    Thid document help to test siemens common rail pump

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    1. A common rail fuel pump was tested on a Merlin S3000 test system. Leak and transfer pressure tests were performed within expected parameters. 2. Pump efficiency and fuel delivery tests showed delivery rates above expected minimums across a range of rail pressures and pump drive percentages. 3. Resistance checks for the pressure control valve and suction control valve were within expected ranges under different temperature conditions.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    267 views10 pages

    Siemens Pump Test Plans 4

    Uploaded by

    DJAMel L
    1. A common rail fuel pump was tested on a Merlin S3000 test system. Leak and transfer pressure tests were performed within expected parameters. 2. Pump efficiency and fuel delivery tests showed delivery rates above expected minimums across a range of rail pressures and pump drive percentages. 3. Resistance checks for the pressure control valve and suction control valve were within expected ranges under different temperature conditions.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
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    of 10

    S3000 Common Rail

    Test System
    TEST DATA

    D
    LT
    Pump Designation:- 5WS40008 Testing Prerequisites
    Inlet Feed Pressure - 0.2 BAR
    Type Designation:-
    Test Oil Specification- ISO4113

    S
    Manufacturer I.D.:- PSA 9658176080
    Test Oil Temperature- 40 deg C

    EM
    Engine:- DV4TD
    Direction of Rotation - Clockwise

    ST
    Remove injector pipes from test rail and blank off with T031- 3005
    Connect Fuel Pump Cable T031- 3001 to Bosch type Pressure Control Valve (PCV) in
    SY
    test rail. Connect Aux cable to Fuel pump PCV. Set Control valve switch to PCV.
    Supply Suction Control Valve (SCV) with 5.5V or remove and fit T016- 698 transfer
    pressure adaptor.

    1. LEAK TEST
    EL

    Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments


    S

    1 350 250 15 Secs No Unusual noise


    IE

    2 2000 1000 3 Mins No Leaks and


    No abnormal
    D

    Temperature rise.
    N
    LI

    2. TRANSFER PRESSURE
    ER

    Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure


    BAR
    M

    1 400 230 2.5- 3.5


    2 1000 1000 4.0
    3 2000 1600 4.5

    MERLIN S3000 COMMON RAIL TEST SYSTEM


    3. PUMP EFFICIENCY

    Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031- 3001.
    Set S3000 Test Unit to PCV

    D
    Test Bench Speed - RPM Rail Pressure Comments Delivery
    BAR CC/1000

    LT
    1 1000 500 600
    2 1000 1000 540 or more

    S
    4. FUEL DELIVERY/ SCV TEST

    EM
    Refit SCV to pump and connect pump lead T031- 3001. Set control valve switch to
    SCV.
    Connect Aux lead to PCV and operate Aux switch
    Fit Bosch type PCV to rail (ie 0281002872)

    ST
    Test Bench Speed - RPM Pump DRV Comments Delivery
    % CC/1000
    SY
    1 1000 60 600
    2 1000 80 200 or more
    3 1000 90 0
    S EL
    IE

    5. PCV / SCV RESISTANCE CHECKS

    Test Bench Speed - RPM PCV Resistance SCV Resistance INLET FUEL
    D

    TEMP C

    1 - 2.8-3.2 2.4-2.6 20
    N

    2 - 3.4-3.8 2.9-3.2 40
    LI
    ER
    M

    MERLIN S3000 COMMON RAIL TEST SYSTEM


    S3000 Common Rail
    Test System
    TEST DATA

    D
    LT
    Pump Designation:- 5WS40018 Testing Prerequisites
    Inlet Feed Pressure - 0.2 BAR
    Type Designation:-
    Test Oil Specification- ISO4113

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

    EM
    Engine:-
    Direction of Rotation - Clockwise

    ST
    Remove injector pipes from test rail and blank off with T031- 3005
    Connect Fuel Pump Cable T031- 3001 to Bosch type Pressure Control Valve (PCV) in
    SY
    test rail. Connect Aux cable to Fuel pump PCV. Set Control valve switch to PCV.
    Supply Suction Control Valve (SCV) with 5.5V or remove and fit T016- 698 transfer
    pressure adaptor.

    1. LEAK TEST
    EL

    Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments


    S

    1 350 250 15 Secs No Unusual noise


    IE

    2 2000 1000 3 Mins No Leaks and


    No abnormal
    D

    Temperature rise.
    N
    LI

    2. TRANSFER PRESSURE
    ER

    Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure


    BAR
    M

    1 400 230 2.5- 3.5


    2 1000 1000 4.0
    3 2000 1600 4.5

    MERLIN S3000 COMMON RAIL TEST SYSTEM


    3. PUMP EFFICIENCY

    Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031- 3001.
    Set S3000 Test Unit to PCV

    D
    Test Bench Speed - RPM Rail Pressure Comments Delivery
    BAR CC/1000

    LT
    1 1000 500 750>
    2 1000 1000 700>

    S
    4. FUEL DELIVERY/ SCV TEST

    EM
    Refit SCV to pump and connect pump lead T031- 3001. Set control valve switch to
    SCV.
    Connect Aux lead to PCV and operate Aux switch
    Fit Bosch type PCV to rail (ie 0281002872)

    ST
    Test Bench Speed - RPM Pump DRV Comments Delivery
    % CC/1000
    SY
    1 1000 60 750>
    2 1000 80 250 >
    3 1000 90 0
    S EL
    IE

    5. PCV / SCV RESISTANCE CHECKS

    Test Bench Speed - RPM PCV Resistance SCV Resistance INLET FUEL
    D

    TEMP C

    1 - 2.8-3.2 2.4-2.6 20
    N

    2 - 3.4-3.8 2.9-3.2 40
    LI
    ER
    M

    MERLIN S3000 COMMON RAIL TEST SYSTEM


    S3000 Common Rail
    Test System
    TEST DATA

    D
    LT
    Pump Designation:- 5WS40094 Testing Prerequisites
    Inlet Feed Pressure - 0.2 BAR
    Type Designation:- A2C59511609
    Test Oil Specification- ISO4113

    S
    Manufacturer I.D.:- FORD 1355053
    Test Oil Temperature- 40 deg C

    EM
    Engine:- LYNX
    Direction of Rotation - Clockwise

    ST
    Remove injector pipes from test rail and blank off with T031- 3005
    Connect Fuel Pump Cable T031- 3001 to Pressure control valve (PCV) in test rail.
    Connect 5.5V supply to fuel pump Suction Control Valve (SCV)
    SY
    1. LEAK TEST
    EL

    Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments

    1 350 250 15 Secs No Unusual noise


    S

    2 2000 1000 3 Mins No Leaks and


    No abnormal
    IE

    Temperature rise.
    D
    N

    2. TRANSFER PRESSURE
    LI

    Fit Transfer pressure adaptor T016- 698 in place of PUMP SCV and connect test bench
    pressure gauge.
    ER

    Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure


    BAR
    M

    1 400 230 2.5-3.5


    2 1000 1000 4.0
    3 2000 1600 4.0

    MERLIN S3000 COMMON RAIL TEST SYSTEM


    3. PUMP EFFICIENCY

    Remove PCV and insert Blank T031- 3704.


    Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031- 3001.
    Set S3000 Test Unit to PCV

    D
    Test Bench Speed - RPM Rail Pressure Comments Delivery
    BAR CC/1000

    LT
    1 1000 500 740
    2 1000 1000 660 or more
    3 1000 1600 590 or more

    S
    EM
    4. FUEL DELIVERY/ SCV TEST

    Refit SCV to pump and connect pump lead T031- 3001


    Remove PCV and fit Blank T031- 3704

    ST
    Fit Bosch type PCV to rail (ie 0281002872)

    Test Bench Speed - RPM Pump DRV Comments Delivery


    % CC/1000
    SY
    1 1000 60 800
    2 1000 80 200 or more
    3 1000 90 0
    S EL
    IE

    5. PCV / SCV RESISTANCE CHECKS


    D

    Test Bench Speed - RPM PCV Resistance SCV Resistance INLET FUEL
    TEMP C

    1 - 2.8-3.2 2.4-2.6 20
    N

    2 - 3.4-3.8 2.9-3.2 40
    LI
    ER
    M

    MERLIN S3000 COMMON RAIL TEST SYSTEM


    S3000 Common Rail
    Test System

    TEST DATA

    PUMP DATA TEST CONDITIONS


    PART No: 5WS-40157 INLET FEED: 0.2 BAR
    TYPE: A2C59511314 TEST OIL: ISO 4113
    O.E.M. REF: FORD/JAGUAR TEST OIL TEMP: 40C
    LAND ROVER/PSA ROTATION: A/CLOCKWISE
    ENGINE: LION V6

    Remove injector pipes from test rail and blank off with T031-3005.
    Connect cable T031-3001 to Bosch type pressure control valve (PCV) in test rail.
    Connect aux. cable to fuel pump PCV.
    Set control valve (SCV) with 5.5V or remove and fit T016-698 transfer pressure adaptor.

    1. LEAK TEST
    Bench speed Rail Pressure
    Test Conditions Comments
    RPM BAR

    1 350 250 15 seconds No unusual noise

    No leaks and no abnormal


    2 2000 1000 3 minutes
    temperature rise

    2. TRANSFER PRESSURE
    Bench speed Rail Pressure
    Test Comments Transfer Pressure BAR
    RPM BAR

    1 400 230 2.5-3.5

    2 1000 1000 4.0


    3 2000 1600 4.5

    3. PUMP EFFICIENCY
    Bench speed Rail Pressure
    Test Comments Delivery cc/1000 shots
    RPM BAR

    1 1000 500 850


    2 1000 1000 780 or more

    1| MERLIN S3000 COMMON RAIL TEST SYSTEM


    4. FUEL DELIVERY/SCV TEST
    Bench speed Pump Drive
    Test Comments Delivery cc/1000 shots
    RPM %

    1 1000 60 850

    2 1000 80 200 or more


    3 1000 90 0

    5. PCV/SCV RESISTANCE CHECKS


    Bench speed PCV Resistance SCV Resistance Inlet Fuel Temperature
    Test
    RPM C
    1 - 2.8-3.2 2.4-2.6 20
    2 - 3.4-3.8 2.9-3.2 40

    2| MERLIN S3000 COMMON RAIL TEST SYSTEM


    S3000 Common Rail
    Test System
    TEST DATA

    D
    LT
    Pump Designation:- 5WS40809 Testing Prerequisites
    Inlet Feed Pressure - 0.2 BAR
    Type Designation:- -
    Test Oil Specification- ISO4113

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

    EM
    Engine:- DW10BTED
    Direction of Rotation - Clockwise

    ST
    Remove injector pipes from test rail and blank off with T031- 3005
    Connect Fuel Pump Cable T031- 3001 to Bosch type Pressure Control Valve (PCV) in
    SY
    test rail. Connect Aux cable to Fuel pump PCV. Set Control valve switch to PCV.
    Supply Suction Control Valve (SCV) with 5.5V or remove and fit T016- 698 transfer
    pressure adaptor.

    1. LEAK TEST
    EL

    Test Bench Speed - RPM Rail Pressure - BAR Conditions Comments


    S

    1 350 250 15 Secs No Unusual noise


    IE

    2 2000 1000 3 Mins No Leaks and


    No abnormal
    D

    Temperature rise.
    N
    LI

    2. TRANSFER PRESSURE
    ER

    Test Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure


    BAR
    M

    1 400 230 2.5- 3.5


    2 1000 1000 4.0
    3 2000 1600 4.5

    MERLIN S3000 COMMON RAIL TEST SYSTEM


    3. PUMP EFFICIENCY

    Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031- 3001.
    Set S3000 Test Unit to PCV

    D
    Test Bench Speed - RPM Rail Pressure Comments Delivery
    BAR CC/1000

    LT
    1 1000 500 700
    2 1000 1000 630 or more

    S
    4. FUEL DELIVERY/ SCV TEST

    EM
    Refit SCV to pump and connect pump lead T031- 3001. Set control valve switch to
    SCV.
    Connect Aux lead to PCV and operate Aux switch
    Fit Bosch type PCV to rail (ie 0281002872)

    ST
    Test Bench Speed - RPM Pump DRV Comments Delivery
    % CC/1000
    SY
    1 1000 60 800
    2 1000 70 400 or more
    3 1000 90 0
    S EL
    IE

    5. PCV / SCV RESISTANCE CHECKS

    Test Bench Speed - RPM PCV Resistance SCV Resistance INLET FUEL
    D

    TEMP C

    1 - 2.8-3.2 2.4-2.6 20
    N

    2 - 3.4-3.8 2.9-3.2 40
    LI
    ER
    M

    MERLIN S3000 COMMON RAIL TEST SYSTEM

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