Marine Test Equipment

Merlin Diesel

Products

DC 80-EM Test Stand

DC 80-EM Test Stand

The Merlin DC 80-EM is a low profile test stand, designed principally for the calibration of larger, single cylinder fuel injection pumps as found in marine, rail and heavy-duty industrial applications. The DC 80-EM has Flywheel, Inertia and drive specifications tailored to suit customer requirements.

Model DC 80-EM incorporates the Merlin S600M/20 positive displacement metering unit, replacing graduates fitted to the standard unit. Monitoring and measurement in bar graph and numeric format on a 10″ TFT colour display. Input/output data and control of measuring system is either by touch screen menu or soft touch push button switches.

APPLICATIONS

  • MPU 300-1 Uprated cambox for W46/ZA40S size/type pumps (300mm).
  • MPU 300 General purpose heavy duty cambox generally for up to 35 mm test cam lift (300mm).
  • MPU 50 For EDM, Woodward, Caterpillar 3500 EUI & MUI, Volvo, Scania, Iveco Eui (125mm or 175).
  • MPU 45 For L’Orange, Ruston, Woodward and Allen unit injectors (175mm).
  • MPC175 1,3 or 4 cylinder cambox with maximum 24mm test cam lift (175mm).
  • CAT 3600 Special production cambox for Caterpillar 3600 mechanical unit injector.
  • Can cater for up to 50mm cam lift and 50mm plunger Diameter units.

A  unique robust heavy duty design weighing 5080kg the DC 80-EM gives the customer multiple options to meet the challenges of testing industrial size Bucket and Roller type pumps.

A DC Thyristor controlled, fan vented motor is controlled via a rotary potentiometer with a variable ramp rate pre-set by digital control.

Water cooled heat exchanger with microprocessor-based digital controller with thermocouple.

Large scaled graduates for high volume accuracy.

Flywheel in excess of ISO standards.

Mobile calibrating and injector mounting rigs are also available for testing heavy-duty multi-cylinder fuel injection pump (C series/R series).

DRIVE MOTOR: 110hp (82kw)
SPEED RANGE: 30-600 rpm
DISPLAY:                                S600M/20 Measuring system 10” TFT Colour display
MEASURING RANGE:        50-20,000 mm³/stroke
TEST OIL SUPPLY PUMP: 1320 litres/hr
LUBE OIL SUPPLY PUMP: 363 litres/hr
TEST OIL FEED PRESSURE: 0-9 bar
FLYWHEEL: 2300kg
FLOWMETER: 2-22 litres/min
TACHOMETER: Digital display, accuracy ± 1 rpm with 0.5 seconds update
WATER SUPPLY:                  750 litres/hr min 3 bar required
TEMPERATURE CONTROL: 0-60°C  ±1°C at 40°C
ELECTRICAL SUPPLY: 220 Volts 3 Phase 50Hz (customer specification)
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
WORK TABLE: 300mm Centre Height
DIMENSIONS
HEIGHT: 1820mm
LENGTH: 3700mm
WIDTH: 1770mm
WEIGHT: 5080kg
DC 80 Test Stand

DC 80 Test Stand

The Merlin DC 80 is a low profile test stand, designed principally for the calibration of larger, single cylinder fuel injection pumps as found in marine, rail and heavy-duty industrial applications. The DC 80 has Flywheel, Inertia and Drive specifications tailored to suit customer requirements.

APPLICATIONS

  • MPU 300-1 Uprated cambox for W46/ZA40S size/type pumps (300mm).
  • MPU 300 General purpose heavy duty cambox generally for up to 35 mm test cam lift (300mm).
  • MPU 50 For EDM, Woodward, Caterpillar 3500 EUI & MUI, Volvo, Scania, Iveco Eui (125mm or 175).
  • MPU 45 For L’Orange, Ruston, Woodward and Allen unit injectors (175mm).
  • MPC175 1,3 or 4 cylinder cambox with maximum 24mm test cam lift (175mm).
  • CAT 3600 Special production cambox for Caterpillar 3600 mechanical unit injector.
  • Can cater for up to 50mm cam lift and 50mm plunger Diameter units.

A  unique robust heavy duty design weighing 3000kg the DC 80 gives the customer multiple options to meet the challenges of  testing industrial size Bucket and Roller type pumps.

A DC Thyristor controlled, fan vented motor is controlled via a rotary potentiometer with a variable ramp rate pre-set by digital control.

Water cooled heat exchanger with microprocessor-based digital controller with thermocouple.

Large scaled graduates for high volume accuracy.

Flywheel in excess of ISO standards.

Mobile calibrating and injector mounting rigs are also available for testing heavy-duty multi-cylinder fuel injection pump (C series/R series).

DRIVE MOTOR:  110 hp (82kw)
SPEED RANGE: 30-600 rpm
DISPLAY: LED & Gauges
MEASURING RANGE: 1 x 0-250 mm³, 1 x 0-1000 mm³ , 1 x 7000 mm³ capacity
TEST OIL SUPPLY PUMP: 1320 litres/hr
LUBE OIL SUPPLY PUMP: 363 litres/hr
TEST OIL FEED PRESSURE: 0-9 bar
FLYWHEEL: 2300kg
FLOWMETER: 2-22 litres/min
TACHOMETER: Digital display, accuracy ± 1 rpm with 0.5 seconds update
WATER SUPPLY: 750 litres/hr min 3 bar required
TEMPERATURE CONTROL: 0-60°C  ±1° C at 40°C
ELECTRICAL SUPPLY: 220 Volts 3 Phase 50Hz (customer specification)
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
WORK TABLE: 300mm Centre Height
DIMENSIONS
HEIGHT: 1650mm
LENGTH: 3250mm
WIDTH: 1500mm
WEIGHT: 50880kg
MK6 Test Stand

MK6 Test Stand

The Merlin MK6 series are designed for the calibration of larger, single and multi-cylinder fuel injection pumps as fitted in marine, rail and heavy duty industrial applications.

Thyristor—controlled DC motor provides infinitely variable stepless drive in both directions, with pre-selection of speeds. Zero droop from maximum to minimum load provides for accurate governor setting.

Two 2.5 Kw heater elements fitted in test oil tank. Microprocessor-based digital controller with thermo-couple.

A selection of mobile injector mount/calibration units, camboxes and fuel pump mounting brackets are available.

Also available with either integral or free standing remote control unit and fully compatible with Merlin’s mobile calibration rig (C415) and injector rig (R415).

INJECTION

Injection is via the R415 Mobile Cylinder Injector Mounting Unit.

  • The unit will accept standard ‘T’, ‘S’ and orifice plate test injectors for multi-cylinder fuel pumps.
  • A heavy duty damper and valve selector system is incorporated for testing single cylinder fuel pumps.
  • Single cylinder test injectors are positioned remotely on a universal fixture mounted on the test bench bed.

METERING

Metering is via the C415 Mobile Calibration Unit.

  • Solenoid operated bottom fill/bottom drain graduates.
  • The unit has 12 x 0-1000mm³graduates for multi-cylinder pumps.
  • 3 additional graduates as follows for single cylinder pump testing:
  • 200mm³
  • 1000mm³
  • 7000mm³
  • Electronic shot count unit range 1 to 9999 adjustable in single selectable increments, display indicates decreasing Count down.

Full Acoustic enclosure can be provided.

DRIVE MOTOR:  60hp (45kw)
SPEED RANGE: 30-1600rpm
DISPLAY: LED & Gauge
MEASURING RANGE: R Series injector mounting unit
TEST OIL SUPPLY PUMP: 1320 litres/hr
TEST OIL FEED PRESSURE: 363 litres/hr
FLYWHEEL: Inertia of 63 kgm²
FLOWMETER:  C Series calibration units
TACHOMETER: ± 1 rpm with 0.5 second updates
WATER SUPPLY: Water cooled heat exchanger
TEMPERATURE CONTROL: 0-60ºC ± 1ºC  at  40ºC
ELECTRICAL SUPPLY: 415v, 3 phase 60Hz
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365.
WORK TABLE: 300 mm Centre height
DIMENSIONS
HEIGHT: 1760mm
LENGTH: 3250mm
WIDTH: 1758mm
WEIGHT: 5080kg
H12-30E Test Stand

H12-30E Test Stand

The Merlin H12-30E Test Stand has been designed principally to test heavy duty in-line, V or single cylinder diesel fuel Injection pumps.

A selection of mobile injector mount/calibration units, camboxes and fuel pump mounting brackets are available to enable testing of a variety of pump types.

Options are available in 4, 6, 8, 16 and 18 cylinder capacity.

Remote control panel duplicates motor start/stop, shot-count start/drain and speed control only and is designed to locate either side of test bench bulkhead. When plugged into the socket the relevant controls on the front panel are disabled.

Two 2.5 Kw heater elements fitted in test oil tank. Microprocessor-based digital controller with thermo-couple.

INJECTION

Injection is via the R series Mobile Cylinder Injector Mounting Unit.

  • The unit will accept standard ‘T’, ‘S’ and orifice plate test injectors for multi-cylinder fuel pumps.
  • A heavy duty damper and valve selector system is incorporated for testing single cylinder fuel pumps.
  • Single cylinder test injectors are positioned remotely on a universal fixture mounted on the test bench bed.

METERING

Metering is via the C series Mobile Calibration Unit.

  • Solenoid operated bottom fill/bottom drain graduates.
  • The unit has 12 x 0-1000mm³graduates for multi-cylinder pumps.
  • 3 additional graduates as follows for single cylinder pump testing:

200mm³

1000mm³

7000mm³

  • Electronic shot count unit range 1 to 9999 adjustable in single selectable increments, display indicates decreasing count down.
DRIVE MOTOR:  40hp (30kw)
SPEED RANGE: 0-4200 rpm
DISPLAY: LED & Gauges
MEASURING RANGE: R series injector mounting units
TEST OIL SUPPLY PUMP: 2280 litres/hr
TEST OIL FEED PRESSURE: 363 litres/hr
LUBE OIL SUPPLY PUMP: 0-7 bar
FLYWHEEL: Inertia value 4.9 kgm²
FLOWMETER: C series calibration units
TACHOMETER: ± 1 rpm with 0.5 seconds update
WATER SUPPLY:  270 litres/hr at 2-3 bar required
TEMPERATURE CONTROL:  0-50°C,  ±1° C at 40°C
ELECTRICAL SUPPLY:  380Volts/ 3 Phase/ 50Hz
CALIBRATION FLUID:  Shell Calibration Fluid 4113, now S9365.
WORK TABLE:  175mm Centre height
DIMENSIONS
HEIGHT: 1530mm
LENGTH: 2640mm
WIDTH: 860mm
WEIGHT: 2000kg

 

S450-1 Marine Injector Tester

S450-1 Marine Injector Tester

The S450-1 has been designed for the performance testing of larger high pressure diesel fuel injectors as found in rail, marine and power generation applications.

The S450-1 is air operated, eliminating operator fatigue and is designed to carry out all standard tests:

  • Nozzle opening pressure
  • Chatter test (atomization)
  • Spray pattern
  • Seat leakage
  • Back-leak.

A variable pumping rate allows for critical analysis of nozzle spray form and line pressure can be held to enable stable pressure dry seat testing.

During atomization the large illuminated spray chamber with built in fume extraction system offers a clear view of the nozzle tip.

The S450-1 is supplied with a dual scale analogue pressure gauge and the Merlin S500-2 digital display injector opening pressure monitor and integral printer.

The S500-2 has been designed for accurate performance testing, production line testing and quality over checking of diesel fuel injectors and nozzles.

Individual test results can be recorded on the S500-2’s built-in printer.

The robust self-draining horizontal worktable will accommodate the largest of injectors. Quick release V-clamps secure the injector in the working position and if required, special mountings can be manufactured to customer requirements.

PUMPING UNIT: Air operated hydraulic pump unit supplied by normal workshop air supply
PRESSURE RANGE: 0-10000 psi (0-700 bar) or 0-15000 psi (0-1000 bar) depending on model
DISPLAY: S500-2 Monitor , dual scale analogue pressure gauge
FLOW CONTROL VALVE: Provides full to minimum flow for critical testing
HIGH PRESSURE TEST PIPES: M22 x 1.5 M14 x 1.5 other pipes available M24 x 1.5, M27 x 1.5, M30 x 1.5
SPRAY CHAMBER: Illuminated chamber, safety switch door operation
FUME EXTRACTION: Variable rate air operated extraction system
FUEL TANK: 100 litres  Capacity
FILTRATION: Replaceable cartridge spin-on element (5 micron rating)
AIR SUPPLY: 6.2 – 6.9 bar required
ELECTRICAL SUPPLY: 220/240v/1PH/50 Hz customer  specifications on request
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365.
WORK TABLE: The standard V-clamps  will accommodate  T, U and V size
DIMENSIONS
HEIGHT: 1360mm
LENGTH: 1325mm
WIDTH: 850mm
WEIGHT: 250kg
S450-CR Marine Injector Tester

S450-CR Marine Injector Tester

The S450-CR has been designed for the performance testing of larger high pressure common rail diesel fuel injectors as well as conventional injectors found in rail, marine and power generation applications.

The S450-CR is air operated, eliminating operator fatigue and is designed to carry out all standard tests:

  • Nozzle opening pressure
  • Chatter test (atomization)
  • Spray pattern
  • Seat leakage
  • Back-leak.

A variable pumping rate allows for critical analysis of nozzle spray form and line pressure can be held to enable stable pressure dry seat testing.

During atomization the large illuminated spray chamber with built in fume extraction system offers a clear view of the nozzle tip.

The Merlin S600/5 digital injector opening pressure/back-leak timing monitor has been designed for accurate performance testing, production line testing and quality over checking of diesel fuel injectors and nozzles.

Individual test results can be recorded on the S500-2 built in printer.

Injection operation is controlled with the Merlin S300-1M common rail injector test system and fuel delivery is displayed digitally on the S600M-5 metering units TFT display panel.

The robust self-draining horizontal worktable will accommodate the largest of injectors. Quick release V-clamps secure the injector in the working position and if required, special mountings can be manufactured to customer requirements.

PUMPING UNIT: Air operated hydraulic pump unit supplied by normal workshop air supply
PRESSURE RANGE: 0-10000 psi (0-700 bar) or 0-15000 psi (0-1000 bar) depending on model
DISPLAY: S600M/5  10″ touch screen TFT display
RANGE:  (S600M/5) 5-5000 mm³/stroke
SPEED RANGE:  50-800rpm
INJECTOR CONTROL: S300-1M trigger box
FLOW CONTROL VALVE: Provides full to minimum flow for critical testing
HIGH PRESSURE TEST PIPES: M22 x 1.5 M14 x 1.5 other pipes available M24 x 1.5, M27 x 1.5, M30 x 1.5
SPRAY CHAMBER: Illuminated chamber, safety switch door operation
FUME EXTRACTION:       variable rate air operated extraction system
FUEL TANK: 100 litres  Capacity
FILTRATION: Replaceable cartridge spin-on element (5 micron rating)
AIR SUPPLY: 6.2 – 6.9 bar required
ELECTRICAL SUPPLY: 220/240v/1PH/50 Hz
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365.
WORK TABLE: The standard V-clamps  will accommodate  T, U and V size
ELECTRICAL SUPPLY: 220/240V/1PH/50 Hz customer  specifications on request
DIMENSIONS
HEIGHT: 1360mm
LENGTH: 1325mm
WIDTH: 850mm
WEIGHT: 250kg
MERLIN C Series Calibration Unit

MERLIN C Series Calibration Unit

Merlin 400 series calibration and injector mounting units are available in 4, 6, 8, 12, 16 and 18 cylinder versions with options of test graduate capacity.

All versions of the 400 series units are fully compatible with DC40/MK6 test stands and extend the range of these single cylinder test stands to cater for multi-cylinder block pumps as fitted to marine and industrial engines.

They are also standard equipment with the H12-30E Fuel Pump Test Stand. Special versions can be manufactured to the customers requirements.

‘C’ series calibration units operate in tandem with the ‘R’ series injector stands. Heavy duty flexible hoses provide supply and return of test oil to test bench. The standard unit is supplied with 0 – 500cc glass graduates calibrated in increments of 1.0cc divisions. A wide range of graduate options are available from stock or manufactured to suit customer application.

Merlin’s patented solenoid operated bottom fill/bottom drain system eliminates aeration and frothing of test oil normally caused by top fill systems. Bottom fill system enables instant readings to be taken on completion of count sequence. Rapid drain system automatically returns fuel level to a pre-set zero position.

METERING

  • Solenoid operated bottom fill/bottom drain graduates.
  • The unit has 12 x 0-1000mm³ graduates for multi-cylinder pumps.
  • 3 additional graduates as follows for single cylinder pump testing:

200mm³

1000mm³

7000mm³

MERLIN R Series Injector Mounting Unit

MERLIN R Series Injector Mounting Unit

Merlin 400 series calibration and injector mounting units are available in 4, 6, 8, 12, 16 and 18 cylinder versions with options of test graduate capacity.

All versions of the 400 series units are fully compatible with DC40/MK6 test stands and extend the range of these single cylinder test stands to cater for multi-cylinder block pumps as fitted to marine and industrial engines.

They are also standard equipment with the H12-30E Fuel Pump Test Stand. Special versions can be manufactured to the customers requirements.

‘R’ series injector mounting units can be suitably positioned to accommodate various injector pipe lengths and operator convenience. Ease of mobility enables access for quick injector changes to be made.

A built in high pressure damping system ensures injection pulses are reduced to a steady and aeration free flow prior to final calibration.

Injector mounting arrangements can be provided to suit customer requirements. Master injectors are not supplied as standard equipment.

INJECTION

  • The unit will accept standard ‘T’, ‘S’ and orifice plate test injectors for multi-cylinder fuel pumps.
  • A heavy duty damper and valve selector system is incorporated for testing single cylinder fuel pumps.
  • Single cylinder test injectors are positioned remotely on a universal fixture mounted on the test bench bed.
CAT 3600 Cambox

CAT 3600 Cambox

The CAT 3600 is a special production heavy duty cambox for Caterpillar 3600 mechanical unit injector.

Utilising genuine Caterpillar parts (rocker arm) etc! the CAT 3600 gives you a dedicated platform to test the performance of your unit pre and post overhaul.

Test plan and correction specifications provided.

Robustly designed to emulate engine conditions.

The cambox is supplied with test cams, tappet setting studs and pump mounting assemblies.

All heavy duty camboxes are pressure lubricated from the test stand lube oil supply.

SPEED RANGE:  0/900rpm
ROTATION:  A/Clockwise (From Drive End)
TEST OIL SUPPLY PRESSURE:  3 To 3.5 bar
LUBE OIL SUPPLY PRESSURE:  1 bar
TEMPERATURE:  30°C
CAM LIFT: 35mm
CENTRE HEIGHT:  125mm/175mm
CALIBRATION FLUID:  Shell Calibration Fluid 4113, now S9365.
MPC 300 Cambox

MPC 300 Cambox

MPC 300 – General purpose heavy duty cambox generally for up to 35mm test cam lift.

The Merlin MPC300 Multi-purpose Cambox is designed to test the following pump types:-

  • Roller & Bucket
  • Tappet
  • Single cylinder
  • Flange mounted
  • Pump sizes: C,CC, CQ, D, DD, X and Z or their equivalents.

The cambox is supplied with test cams, tappet setting studs and pump mounting assemblies for MTU and Bryce pumps. These are general instructions for mounting to a Merlin test stand. Various tools are supplied for use when changing test cams.

Special versions can also be supplied to suit customer requirements. All heavy duty camboxes are pressure lubricated from the test stand lube oil supply.

SPEED RANGE: 0/500rpm
ROTATION: A/Clockwise (From Drive End)
TEST OIL SUPPLY PRESSURE: 3 To 3.5 bar
LUBE OIL SUPPLY PRESSURE: 1 bar
TEMPERATURE:  30°C
CAM LIFT: 10mm/35mm
CENTRE HEIGHT: 300mm
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365.
MPC 300-1 Cambox

MPC 300-1 Cambox

MPC 300-1 – General purpose heavy duty cambox generally for up to 35mm test cam lift.

The Merlin MPC 300-1 Multi-purpose Cambox is designed to test the following pump types:-

  • Roller & bucket
  • Tappet
  • Single cylinder
  • Flange mounted
  • Pump sizes: W46, ZA40S or their equivalents.

The cambox is supplied with test cams, tappet setting studs and pump mounting assemblies for MTU and Bryce pumps. These are general instructions for mounting to a Merlin test stand. Various tools are supplied for use when changing test cams.

Special versions can also be supplied to suit customer requirements. All heavy duty camboxes are pressure lubricated from the test stand lube oil supply.

SPEED RANGE: 0/500rpm
ROTATION: A/Clockwise (From Drive End)
TEST OIL SUPPLY PRESSURE: 3 To 3.5 bar
LUBE OIL SUPPLY PRESSURE: 1 bar
TEMPERATURE:  30°C
CAM LIFT: 10mm/35mm
CENTRE HEIGHT: 300mm
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365.
MPC 125 Cambox

MPC 125 Cambox

The Merlin MPC 125– Multi-purpose cambox is of heavy duty construction and designed for a smaller Test stand. The Merlin MPC 125 Cambox is designed to test the following pump types:-

  • Roller & bucket
  • Tappet
  • Single cylinder
  • Flange mounted
  • multiple pump sizes

The cambox is supplied with test cams, tappet setting studs and pump mounting assemblies for MTU and Bryce pumps. These are general instructions for mounting to a Merlin test stand. Various tools are supplied for use when changing test cams.

Special versions can also be supplied to suit customer requirements. All heavy duty camboxes are pressure lubricated from the test stand lube oil supply.

SPEED RANGE: 0/500rpm
ROTATION: A/Clockwise (From Drive End)
TEST OIL SUPPLY PRESSURE: 3 To 3.5 bar
LUBE OIL SUPPLY PRESSURE: 1 bar
TEMPERATURE: 30°C
CAM LIFT:  22mm
CENTRE HEIGHT:  125mm
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365

 

MPC 175 Cambox

MPC 175 Cambox

The Merlin 175 cambox is available for testing bucket & roller tappet type fuel pumps and unit injectors. 24mm test cam lift with special profiles to engine manufacturers specification can also be supplied.

Up to 4 pumps with similar cam lift can be tested and balanced at any one time utilizing the full available test bench driving power and flywheel inertia.

Alternatively the cambox can be pre-assembled with any combination of 4 different cam lifts giving greater flexibility and reducing time spent changing cams to suit pump types.

Individual cam followers can be isolated from the drive when testing a single cylinder pump only.

Features include compact design and ease of access to the adjustable plunger for precise setting of pump ‘A’ dimension, high tensile strength camshafts, heavy duty bearings and drive coupling.

All heavy duty camboxes are pressure lubricated from the test stand lube oil supply.

This cambox is also available in 1 and 3 cylinder versions.

SPEED RANGE: 0/500rpm
ROTATION: A/Clockwise (From Drive End)
TEST OIL SUPPLY PRESSURE: 3 To 3.5 bar
LUBE OIL SUPPLY PRESSURE: 1 bar
TEMPERATURE: 30°C
CAM LIFT:  24mm
CENTRE HEIGHT:  175mm
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
S400A-M Injector Tester

S400A-M Injector Tester

The Merlin S400A-M is a 700 bar air operated injector tester used for testing and adjusting smaller marine type injectors, before and after reconditioning. Designed and developed with the following functions:-

  • Opening pressure
  • Chatter test (atomization)
  • Spray pattern
  • Seat leakage
  • Back-leakage

All controls and instruments are grouped together for operator convenience and include the latest Merlin S500-2 display monitor, flow control valve, light and fume extraction control.

Fully sealed air pump unit, robust construction, pneumatically operated via normal workshop air supply.

Illuminated spray chamber to give a good view of injector spray pattern. A variable rate air operated fume extraction system with optional Perspex spray arrestor further assists the extraction operation.

Standard tank features include sight level gauge, quick release filler cap and magnetic drain plug.

Fitted with a heavy duty V-clamp assembly and a M22x1.5 male threaded outlet connector to suit marine injector test pipes available from stock or made to customer specification.

The Merlin S500-2 Display Monitor has been designed for accurate performance testing, production line testing and quality over checking of diesel fuel injectors and nozzles.

The repeatable and reliable digital display of pressure eliminates errors normally found in conventional analogue pressure gauges due to hysteresis in gauge readings,

possible undetected mechanical damage, gauge inaccuracies and gauge needle bounce when setting Nozzle Opening Pressure.

Back leakage timing errors are eliminated due to the absence of having to start and stop a remotely sited mechanical timer.

Print out of test results from the thermal image printer.

 

PRESSURE RANGE: 0-700 bar, psi, MPa or kgf/cm²
PRESSURE: ±1 bar
TIME RANGE: 0-99.9 seconds
TIMING: ±1 second
TRANSDUCER: ±0.1% of full value
LINEARITY: ±1 bar over full range
MEMORY: Data store/recall for injector type test plans
DISPLAY:                LED, Tick/cross symbols advise user of NOP and back-leak pass/fail
COMPENSATION:                                 Automatic compensation for variations in test oil temperature
DIMENSIONS
HEIGHT:  770mm
LENGTH:  600mm
WIDTH: 600mm
WEIGHT: 66km
VM1 & VM5 engine valve re-facing machines

VM1 & VM5 engine valve re-facing machines

The Merlin VM1 & VM5 are engine valve re-facing machines for medium to small Industrial, Rail and Marine applications. Designed and developed with the following functions:-

  • Robust cast iron wheel-head, work-head and bed.
  • All slides fully adjustable and accurately dove-tailed throughout.
  • Easily replaceable wheel-head grinding spindle cartridge, fitted with extra precision bearings.
  • Grinding spindle speed 4000rpm.
  • Wheel-head and work-head independently driven by electric motors, 1⁄2hp and 1⁄2hp respectively.
  • Wet grinding by gear pump.
  • Large capacity coolant tank fitted with filter/sludge trap and drain plug.
  • Wheel-head feed graduated in 0.025mm.
  • Centre pivot locking lever to ensure repeatability of valve angle being ground.
  • Work-head fitted with two self centering, precision chucks to accommodate longer valves.

Both machines can be suppled with steel pedestal cabinet with drawer and storage cupboard.

  • VM1B / VM5B (bench mounted)
  • VM1C / VM5C (cabinet mounted)
VM1 VM5
VALVE STEM CAPACITY: 3.175mm to 25.4mm 19mm to 33mm
VALVE HEAD CAPACITY: Up to 139.7mm Up to 152mm
ANGULAR ADJUSTMENT: 0°-90° 0°-90°
GRINDING HEAD: 1⁄2hp 1⁄20hp
WORK HEAD: 1⁄20hp 1⁄20hp
WET GRINDING: Coolant supply by vane pump  Coolant supply by vane pump
DRESSING: Universal diamond dressing tool Universal diamond dressing tool
WHEEL DIAMETER: Maximum available 150.0mm Maximum available 150.0mm
WHEEL HEAD SPEED:                                4000rpm  4000rpm
WORK HEAD SPEED: 68rpm 68rpm
CHUCKS: 2 x 3 jaw, self-centreing 2 x 3 jaw, self-centreing
ELECTRICAL SUPPLY:  220/250v single phase—380/440v three phase 220/250v single phase—380/440v three phase
VALVE STEADY: 130mm long valve steady will accommodate valve types with extended unsupported valve seats
DIMENSIONS
HEIGHT: 380mm 380mm
LENGTH: 760mm 760mm
WIDTH: 610mm 610mm
WEIGHT: 82kg 120kg
M12A & M16A lapping machines

M12A & M16A lapping machines

The M12A/M16A  machines are self-contained units, intended for the precision lapping of flat surfaces on a wide variety of materials ranging from carbon and plastics to very hard tungsten carbide.

Once the machine is loaded and set in motion the process is automated and electronically timed.

The lapping machines have 406mm (16”) diameter lapping plates and will accept work pieces up to 114mm (4.5”) diameter, which are carried in each of three control rings on the anti-clockwise rotating lapping plate.

All lapping plates and control rings are made of close grained high quality cast iron, the flatness of which is controlled accurately during the operation of the machine.

Lapping compound is a mixture of lapping fluid and abrasive powder, supplied separately and mixed in the pump tank and pumped onto the lapping plate using a flow adjuster.

Waste compound drains into a removable waste tank.

M12A M16A
LAPPING PLATE: (outer diameter) 305mm (12”) 406mm (16”)
CONTROL RINGS x 3 (Inner diameter) 114mm 135mm
TIMER RANGE: 0-60 minutes 0-60 minutes
LAPPING PLATE MOTOR: 1⁄3hp 1⁄3hp
PUMP MOTOR: 1⁄6hp 1⁄6hp
ELECTRICAL SUPPLY: 220/240v-50Hz single phase 220/240v-50Hz single phase
DIMENSIONS
HEIGHT: 436mm 438mm
LENGTH: 590mm 700mm
WIDTH: 410mm 600mm
WEIGHT: 82kg 82kg
S600M Video Metering Unit

S600M Video Metering Unit

The S600M is am positive piston displacement heavy duty metering unit specifically designed for end of production line testing of large single cylinder pumps and unit injectors.

The S600M is also available to the F.I.E. field service operator where more critical over-checking of pump delivery is essential.

Monitoring and measurement is in bar graph and numeric format on a 10″ TFT colour display.

Input/output data and control of measuring system is either by touch screen menu or soft touch push button switches.

The injected fuel displaces the metering piston, this movement is measured by an optical non-contact linear encoder which produces a signal of one pulse per one micron of piston movement.

Control systems and software designed for Merlin compute this signal and displays the fuel delivery on the screen in the measurement units, updates are manually controlled by the operator. An additional signal from the test oil temperature measuring probe located in the piston chamber is used to calculate the volume of displacement at a test oil temperature of 40°C.

The S600M is designed to be completely mobile and therefore does not require to be leveled before operation. The height of the metering unit can be adjusted by 50mm.

Individual test results can be recorded on the built in printer.

OPERATIONAL RANGE S600/5: 5 – 5,000 mm³/stroke
OPERATIONAL RANGE S600M/20: 50 – 20,000 mm³/stroke
SPEED RANGE: 50 rpm Maximum: 1000rpm
DISPLAY: 10″ touch screen TFT display
COMPRESSED AIR SUPPLY: 80 – 100 PSI (5.5 – 6.9 bar)
DATA CAPTURE: Uni-directional RS232 serial data link operating at 1200 baud, 7 data bits, even parity, 1 stop bit.
TACHOMETER: Digital display, accuracy ± 1 rpm with 0.5 seconds update.
TEMPERATURE CONTROL: 0-60°C ± 2° C at 40°C
ELECTRICAL SUPPLY: 110V – 240v, 50/60Hz, single phase.
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
DIMENSIONS
HEIGHT: 1740mm
LENGTH: 765mm
WIDTH: 765mm
WEIGHT: 200kg

 

AUTOLAP 200 Nozzle grinder

AUTOLAP 200 Nozzle grinder

The Merlin Autolap 200 is an injector nozzle seat lapping machine which dispenses with time, consuming hand lapping methods of nozzle reclamation.

A wide range of stone tipped laps are available to service most nozzle sizes from ‘S’ through to ‘V’.

These laps are positioned in a self-centring automatic chuck during the re-seating operation, on completion of which the chuck drive automatically disengages allowing nozzle removal for inspection purposes.

A variable timer control allows for lapping periods of up to 7 minutes in 10 seconds steps. The timer control can be interrupted and re-started during any pre-set period.

Stone tipped lapping tools can be re-dressed on the Merlin NR3B using dressing tool attachment.

Nozzles can be tested on the Merlin S31 or S400 series injector test units.

STANDARD ACCESSORIES: S’ size short and long stem nozzle adaptor
Long weight
Cutting fluid
OPTIONAL ACCESSORIES: Adaptor ‘T’ Size Short Stem
Adaptor American Bosch/Bosch P
Adaptor ‘V ‘Size
Adaptor ‘U’ Size
Adaptor Leyland/Gardner
Adaptor Gardner
ELECTRICAL: 100/120v-1-50/60Hz or 220/240v-1-50/60Hz
DIMENSIONS
HEIGHT: 775mm
LENGTH: 495mm
WIDTH: 356mm
WEIGHT: 80kg
S100A B&W injector tester

S100A B&W injector tester

The Merlin S100A B & W Mobile Injector Test Kit is a self-contained unit for checking the correct operation of B & W injectors. Designed and developed with the following functions:-:-

  • Atomisation.
  • Opening Pressure.
  • Dry Seat Test.
  • Slide Valve Operation.
  • O-ring sealing Pressure Test.

The injector fixture assembly can be mounted into the fume extraction hood of the Merlin 450-1 series of injector testers, or into any suitable customer manufactured spray chamber.

The S100A is fully compatible with the Merlin S500-2 Digital pressure monitoring and printer unit (pictured). The repeatable and reliable digital display of pressure eliminates errors normally found in conventional analogue pressure gauges.

FLOWMETER: 0.2-1.5 l/min
OPENING PRESSURE GAUGE: 1200 bar
WORKING PRESSURE GAUGE: 500 bar
SLIDE VALVE PRESSURE GAUGE: 250 bar
AIR PRESSURE GAUGE: 10 bar
AIR PUMP UNIT: 6 bar
OIL TANK: 46 litres
ELECTRICAL SUPPLY: 220/240v/1PH/50Hz
MERLIN S500-2: (optional) Digital Display with printer
DIMENSIONS
HEIGHT: 1700mm
LENGTH: 500mm
WIDTH: 600mm
WEIGHT: 82kg
S31-M

S31-M

The Merlin S31M is a 700 bar portable hand lever operated injector tester. Used for testing and adjusting conventional marine injectors. Designed and developed with the following functions:-

  • Opening pressure
  • chatter test (atomization)
  • spray pattern
  • seat leakage
  • Back leakage

Built-in Perspex spray arrestor provides continuous circulation of test oil with minimum loss to atmosphere.

Pump unit designed to give trouble free operation by the incorporation of a fuel pump type element, contained in a replacement cartridge.

Uprated actuator shaft/bushes and injector mounting supports for larger marine injectors.

Pump output 1600/1800 mm3 per stroke. Trapped volume limited by design to satisfy injector manufacturers back leak lest requirements.

Lightweight die cast aluminium body with removable operating handle.

 

PRESSURE RANGE: 0-700 Bar, psi (0-10000)
PUMP OUTPUT: ±1 bar
PUMP OUTPUT: 1600/1800 mm3 per stroke
DISPLAY: Gauge
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
THREAD SIZE: M22 x 1.5
DIMENSIONS
HEIGHT: 305mm
LENGTH: 475mm
WIDTH: 965mm
WEIGHT: 48kg
ADDITIONAL THREAD SIZES: M22 x 1.5
M27 x 1.5
M24 x 1.5
M30 x 1.5