Automotive Test Benches

test plan info: testplan@merlindiesel.com

Products

S8000 test stand

S8000 test stand

 

The Merlin S8000 is a fully automatic common rail test bench designed and developed with the following functions:-

Tests BOSCH, DENSO, DELPHI and SIEMENS injectors and pumps.

Tests up to 6 solenoid valve injectors in succession or 1 Piezo injector at once.

Automatically measures and displays delivered fuel quantity.

Tests the seal performance of injectors and delivery under different working conditions as follows:-

  • Idle
  • Pre-injection
  • Mid-range
  • Max fuel

Operator can add data and customer information which can be printed and saved.

Equipped with original Bosch CP3.3 pump, rail, DRV and ZME.

Test oil temperature controlled to 40±2 °C, built-in cooling system.

Feeding pressure can be adjusted 0-6 bar.

INJECTOR TEST:

  • High pressure cleaning to flush out the nozzle.
  • Test injection & return volume under VL, TL, LL, VE and VE2 status.
  • Atomization test to check for blocked nozzles.
  • Sealing test to check for leaks.
  • Tests up to 6 solenoid valve injectors in succession or 1 Piezo injector at once. Tests Piezo injectors.

PUMP TEST:

  • Automatically tests volume, pump transfer pressure and ZME performance for Bosch, Delphi, Siemens and Denso common rail pumps.

CODING

  • Merlin S1000 all makes coding is available on this test bench.
  • Capability to generate IMA C2i/C3i and QR Correction code for each individual Injector.
DRIVE MOTOR: 22hp (16.5kw) Variable Frequency Control
SPEED RANGE: 0-3500rpm
DISPLAY: 19” LCD
FLOWMETER: 2 x Kobold Flowmeters
TEST OIL SUPPLY PUMP: Bosch CP3.3
HIGH PRESSURE AND DRV: Bosch Original Parts
TEST RANGE OF RAIL PRESSURE: 0-2200 bar
TEST OIL SUPPLY FILTRATION: Mesh Tank Strainer and 2 Spin-On 2 Micron Cartridge Elements
FLOWMETER FILTRATION: 1 Spin-On Cartridge Element and 1 In-Line Filter
TEST OIL TANK: Capacity 35 litres
OIL COOLER UNIT: Refrigerant Gas R404A
TEMPERATURE: 0-60° C ±2° C at 40°C
ELECTRICAL SUPPLY: 380V /3 phase /50Hz
CABLE: 4-6mm 2 x 5 core
CALIBRATION FLUID: Shell Calibration Fluid 4113 now S9365
DIMENSIONS
HEIGHT: 1900mm
LENGTH: 900mm
WIDTH: 1800mm
WEIGHT: 850kg
S4000 MK 2 test stand

S4000 MK 2 test stand

The Merlin S4000 MK 2 is a fully automatic common rail test bench designed and developed with the following functions:-

Tests BOSCH, DENSO, DELPHI and SIEMENS injectors.

Tests solenoid valve and Piezo injectors.

Automatically measures and displays delivered fuel quantity.

Tests the seal performance of injectors and delivery under different working conditions as follows:-

  • Pre-injection
  • Idle
  • Mid-range
  • Max fuel

Operator can add data and customer information. This data can be viewed printed and saved.

Equipped with original Bosch CP1 pump, rail, DRV and ZME.

Test oil temperature controlled to 40±2 °C, built-in cooling system.

Feeding pressure can be adjusted 0-6 bar.

INJECTOR TESTER

  • High pressure cleaning to flush out the nozzle.
  • Test injection & return volume under VL, TL, LL, VE and VE2 status.
  • Atomization test to check for blocked nozzles.
  • Sealing test to check for leaks.

CODING

  • Merlin S1000 all makes coding is available on this test bench.
  • Capability to generate IMA C2i/C3i and QR Correction code for each individual injector.
DRIVE MOTOR: 10hp (7.5kw)  Variable frequency control
SPEED RANGE: 0-3500rpm
DISPLAY: 19” LCD
FLOWMETER: High capacity Flowmeter
TEST OIL SUPPLY PUMP:   Bosch CP1
HIGH PRESSURE RAIL AND DRV: Bosch original parts
TEST RANGE OF RAIL PRESSURE: 0-1800 bar
TEST OIL SUPPLY FILTRATION: Mesh tank strainer and 1 spin-on 2 micron cartridge element
FLOWMETER FILTRATION: 1 spin-on cartridge element and 1 in-line filter
TEST OIL TANK:                     Capacity 28 litres
TETS OIL HEATER: 1 kw rating
OIL COOLER UNIT: Refrigerant gas R404A
TEMPERATURE CONTROL: 0-60° C ±2°C at 40°C
ELECTRICAL SUPPLY: 380v  /3 phase / 50Hz
CABLE: 4-6mm 2 x 5 core
DIMENSIONS
HEIGHT: 1200mm
LENGTH: 900mm
WIDTH: 1650mm
WEIGHT: 350kg

 

S9000 HEUI TEST STAND

S9000 HEUI TEST STAND

The Merlin S9000 is a dual purpose test stand incorporating HEUI and Common Rail technology. Having both Hydraulic and high Pressure components allows this unique platform to give your workshop not only the flexibility of the all makes common rail, but also Caterpillar, Navistar and Ford off highway, HEUI capabilities. The S9000 can also be coupled with Merlins S1000 all makes coding giving you even more control of the quality of your product. Designed and developed with the following functions:-

HEUI:

  • Tests Caterpillar C7/C9. Navistar & ford powerstroke 3126 type.
  • Hydraulic oil leak test.
  • Hydraulic oil return over four deliveries.
  • Injection quantity’s over four deliveries.
  • Sealing test to check for leaks.
  • Touch Screen
  • Built in WIFI for remote Assistance,Training,Upgrade.
  • Customer printouts.

COMMON RAIL:

  • Tests Bosch,Denso,Delphi and Siemens injectors.
  • High pressure cleaning to flush out the nozzle.
  • Test injection & return volume under VL, TL, LL, VE and VE2 status.
  • Sealing test to check for leaks.
  • Tests Piezo injectors.

CODING:

  • Merlin S1000 all makes coding is available on this test bench.
  • Capability to generate IMA, C2i/C3i and QR Correction code for each individual Injector.
TEST OIL DRIVE MOTOR: 5hp (4kw)
LUBE OIL DRIVE MOTOR: 3hp  (2.2kw)
DISPLAY: 19” touch screen LCD
TEST OIL FLOWMETER: German
HYDRAULIC FLOWMETER: German
TEST OIL SUPPLY PUMP: Bosch CP3.3
HIGH PRESSURE RAIL AND DRV: Bosch original parts
RANGE OF RAIL PRESSURE: 0-1800 bar
RANGE OF OIL PRESSURE: 0-250 bar
TEST OIL SUPPLY FILTRATION:  Mesh tank strainer and 1 spin-on 2 micron cartridge element
FLOWMETER FILTRATION: 1 spin-on cartridge element and 1 in-line filter
TEST OIL TANK: Capacity 19 litres
HYDRAULIC OIL TANK: Capacity 19 litres
TEST/HYDRAULIC OIL HEATER: 1kw rating
OIL COOLER UNIT: Refrigerant gas R404A
TEMPERATURE  CONTROL: 0-60° C ±2° C at 40°
ELECTRICAL SUPPLY: 380v  /3 phase  /50Hz
DIMENSIONS
HEIGHT: 1450mm
LENGTH: 900mm
WIDTH: 1550mm
WEIGHT: 500kg
MM Series Test Stand

MM Series Test Stand

The Merlin MM Series are a direct drive test stands principally designed for the calibration of automotive fuel injection pumps. Designed and developed with the following functions:-

APPLICATIONS:

  • A type Inline BOSCH, SIMMS and MINIMEC
  • Mechanical BOSCH, DELPHI, STANADYNE, DENSO and ZEXEL
  • HK1400 All makes Cambox
  • Submersible pumps (appropriate Cambox required)

Robust compact design with all steel frame construction. Water cooled and internally heated with air and power supply.

A solid state electronic shot counter, range 1-9999, incorporates a manual interrupter and is combined with a digital tachometer display.

8 or 12 cylinder scale graduates for greater accuracy.

10hp (7.5 kw) or 15hp (11.0 kw) available.

Closed displacement system with test injectors fitted with lSO4010 nozzles as standard. The injectors incorporate vent valves for rapid high pressure phasing and pump venting. The calibrating head is pivot mounted for right or left hand operation.

All gauges are grouped on one panel and face the control panel for ease of reading. A compound pressure/vacuum gauge indicates feed pressure or vacuum as required. Independently driven supply/Lube pump.

Supplied complete with test injectors and anti-backlash coupling.

Basic in-line, rotary mounting kits.

Factory fitted equipment: Variable DC supply, lube oil supply.

 

DRIVE MOTOR: 10hp & 15hp (7.5kw & 11kw)
SPEED RANGE: 0-4100rpm
DISPLAY: LED & Gauges
MEASURING RANGE: 8/12 x 0-100cc capacity 1 x 0-100cc (back leak)
TEST OIL SUPPLY PUMP: 435 litres/hr (tandem pump)
LUBE OIL SUPPLY PUMP: 435 litres/hr (tandem pump)
TEST OIL FEED PRESSURE: 0-7 bar
FLYWHEEL: Inertia value: 0.25 kgm²
FLOWMETER: Closed displacement system
TACHOMETER: ± 1 rpm. Updates every 0.5 seconds
WATER SUPPLY: 160 litres/hr min 3 bar required
TEMPERATURE CONTROL: 0-60°C  ±1°C at 40°C
ELECTRICAL SUPPLY: 210-250v / 380-440v / 45-62Hz
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
WORK TABLE: 125mm Centre height
DIMENSIONS
HEIGHT: 1800mm
LENGTH: 1500mm
WIDTH: 680mm
WEIGHT: 463kg
MER 12-20 TEST STAND

MER 12-20 TEST STAND

Merlin’s MER 12-15 is a 15hp (11.0 kw) direct drive test stand and is principally designed for the calibration of automotive fuel injection pumps. Designed and developed with the following functions:-

APPLICATIONS

  • A type Inline BOSCH, SIMMS and MINIMEC.
  • Mechanical BOSCH, DELPHI, STANADYNE DENSO and ZEXEL.
  • HK1400 All makes Cambox.
  • Submersible pumps (appropriate Cambox required).

Multi programmable speed controls along with fully programmable shot and temperature range.

All gauges are grouped on one panel and face the control panel for ease of reading. A compound pressure/vacuum gauge indicates feed pressure or vacuum as required.

Robust compact design with all steel frame construction.

Internally cooled and heated with air and 12v/24v power supply.

Up to 12 cylinder duel scale graduates for grater accuracy.

Independently driven supply pump.

Supplied complete with test injectors and anti-backlash coupling.

Basic in-line, rotary mounting kits.

DRIVE MOTOR: 15hp (11.0 kw)
SPEED RANGE: 0-4000rpm x 10 pre-set speeds
DISPLAY: LED & Gauges
MEASURING RANGE: Dual scale graduates 12 x 45cc-150cc capacity
TEST OIL SUPPLY PUMP: 400 litres/hr
TEST OIL FEED PRESSURE: 0-6 bar
POWER POINT: 12v-24v Sockets
TACHOMETER: Digital display, accuracy ± 1 rpm with 0.5 seconds update
TEMPERATURE CONTROL: 0-60°C ±2° C at 40°C
OIL COOLER UNIT: Refrigerant Gas R404A
ELECTRICAL SUPPLY: 380v /3-phase /50-60Hz
CALIBRATION FLUID: 380v /3-phase /50-60Hz
WORK TABLE: 1.25 Centre Height
DIMENSIONS
HEIGHT: 1650mm
LENGTH: 1600mm
WIDTH: 960mm
WEIGHT: 950kg