Injector Testing

Merlin Diesel

Products

S400

S400

The Merlin S400 is a 700 bar manual hand lever operated injector tester used for testing and adjusting conventional automotive injectors. 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.

Left or Right handed operation with a robust construction.

Illuminated spray chamber to give a good view of injector spray form. 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.

Print out of test results from the thermal image printer.

 

DOWNLOAD SPECIFICATIONS

PRESSURE RANGE: 0-700 bar. psi, MPa or kgf/cm²
PRESSURE: ±1 bar
PUMP OUTPUT: 1600/1800 mm³ per stroke
DISPLAY: Analogue gauge
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
THREAD SIZE: M12 X 1.5
Dimensions
HEIGHT: 550mm
LENGTH: 600mm
WIDTH: 560mm
WEIGHT: 66kg
ADDITIONAL ADAPTORS:* T022-003 = M12 x 1.5 split adaptor
T022-004 = M18 x 1.5
T022-006 = 1/4″ BSP (Gardner Injectors)
T022-007 = 9/16″ x 18 UNF
T022-008 = 5/8″ x 18 UNF
T022-009 = M14 x 1.5 (long reach)
Installation details
ELECTRICAL SUPPLY 240/1 phase/50Hz
110v/1 phase/60Hz
*Adaptors sold separately
S400-5

S400-5

The Merlin S400-5 is a 700 bar manual hand lever operated injector tester used for testing and adjusting conventional automotive injectors. 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.

Left or Right handed operation with a robust construction.

Illuminated spray chamber to give a good view of injector spray form. 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.

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

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.

DOWNLOAD SPECIFICATIONS

PRESSURE RANGE:  0-700 bar, psi, MPa or kgf/cm²
TIME RANGE:  0-99.9 seconds
PRESSURE:  ±1 bar
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
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
Dimensions
HEIGHT: 550mm
LENGTH: 600mm
WIDTH: 560mm
WEIGHT: 66kg
Installation details
ELECTRICAL SUPPLY 240v/1 phase/50Hz
110v/1 phase/60Hz
S400-5 CR

S400-5 CR

The Merlin S400-5CR is a 700 bar air operated, automated injector tester used for testing and adjusting Common Rail and conventional automotive injectors. The S400-5CR incorporates the Merlin S500-2 and  the S300-1 common rail trigger box. 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.

Left or Right handed operation with a robust construction.

Illuminated spray chamber to give a good view of injector spray form. 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.

The Merlin S300-1 is a single unit designed to test both electro-hydraulic and piezo type injectors. Designed to operate Bosch, Delphi, Denso and Siemens common rail injectors.

When used in conjunction with a Merlin S400A or S425A air operated injector tester, a common rail injector can be operated sufficiently to observe the nozzle spray pattern and measure the back-leak time.

It can also be used with manually operated injector testers.

Fault detection of injector short circuit, injector open circuit, incorrect injector type connected.

Supplied complete with electrical mains cable, connection cable with 4 adaptor cables to suit Bosch, Denso, Delphi, Piezo and general purpose applications.

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.

Print out of test results from the thermal image printer.

 

DOWNLOAD SPECIFICATIONS

PRESSURE RANGE: 0-700 bar, psi, MPa or kgf/cm²
TIME RANGE: 0-99.9 seconds
PRESSURE: ±1 bar
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
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
INJECTOR  VOLTAGE: 85—135v dc
PULSEWIDTH RANGE: 0.5—3.0ms
REPETITION RATE: 0.75 – 14Hz
FAULT DETECTION: Short circuit, open circuit
Dimensions
HEIGHT: 550mm
LENGTH: 600mm
WIDTH: 560mm
WEIGHT: 66kg
Installation details
ELECTRICAL SUPPLY 240v/1 phase/50Hz
110v/1 phase/60Hz
S400A

S400A

The Merlin S400A is a 700 bar air operated, automated injector tester used for testing and adjusting conventional automotive injectors. 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 form. 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.

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.

DOWNLOAD SPECIFICATIONS

PRESSURE RANGE: 0-700 bar, psi, MPa or kgf/cm²
TIME RANGE: 0-99.9 seconds
PRESSURE: ±1 bar
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
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
Dimensions
HEIGHT: 770mm
LENGTH: 600mm
WIDTH: 560mm
WEIGHT: 66kg
Installation details
ELECTRICAL SUPPLY 240v/1 phase/50Hz
110v/1 phase/60Hz
S400A-CR

S400A-CR

The Merlin S400A-CR is a 700 bar air operated, automated injector tester used for testing and adjusting Common Rail and conventional automotive injectors. The S400A-CR incorporates the Merlin S500-2 and the S300-1 common rail trigger box. 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 form. 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.

The Merlin S300-1 is a single unit designed to test both electro-hydraulic and piezo type injectors. Designed to operate Bosch, Delphi, Denso and Siemens common rail injectors.

When used in conjunction with a Merlin S400A or S425A air operated injector tester, a common rail injector can be operated sufficiently to observe the nozzle spray pattern and measure the back-leak time.

It can also be used with manually operated injector testers.

Fault detection of injector short circuit, injector open circuit, incorrect injector type connected.

Supplied complete with electrical mains cable, connection cable with 4 adaptor cables to suit Bosch, Denso, Delphi, Piezo and general purpose applications.

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.

Print out of test results from the thermal image printer.

 

DOWNLOAD SPECIFICATIONS

PRESSURE RANGE: 0-700 bar, psi, MPa or kgf/cm²
TIME RANGE: 0-99.9 seconds
PRESSURE: ±1 bar
TIMING: ±0.1% of full value
TRANSDUCER: ±1 bar over full range
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
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
INJECTOR VOLTAGE: 85—135v dc
PULSEWIDTH RANGE:  0.5—3.0ms
REPETITION RATE:  0.75 – 14Hz
FAULT DETECTION:  Short circuit, open circuit
Dimensions
HEIGHT: 770mm
LENGTH: 600mm
WIDTH: 560mm
WEIGHT: 66kg
Installation details
ELECTRICAL SUPPLY 240v/1 phase/60Hz
110v/1 phase/60Hz
S425A

S425A

The Merlin S425A is a 700 bar air operated, automated injector tester used for testing and adjusting  2 stage (2 spring) and conventional injectors, before and after reconditioning. Features are basically the same as S400A with an additional high pressure circuit, pressure regulator, gauge and control valves required to operate second stage opening pressure. 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.

Nozzle opening pressure 1 and 2 are digitally displayed and stored to memory for print-out.

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 form. 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.

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.

DOWNLOAD SPECIFICATIONS

PRESSURE RANGE: 0-700 bar, psi, MPa or kgf/cm²
TIME RANGE: 0-99.9 seconds
PRESSURE: ±1 bar
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
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
Dimensions
HEIGHT: 770mm
LENGTH: 600mm
WIDTH: 650mm
WEIGHT: 66kg
Installation details
ELECTRICAL SUPPLY 240v/1 phase/50Hz
110v/1 phase/60Hz
S400A-CRC

S400A-CRC

The Merlin S400A-CRC is a 700 bar air operated, automated injector tester used for testing and adjusting Common Rail and conventional automotive injectors. The S400A-CRC incorporates the Merlin S500-2,S300-1 common rail trigger box and Merlin’s C302 twin calibration unit. Designed and developed with the following functions:-

  • Opening pressure
  • chatter test (atomization)
  • spray pattern
  • seat leakage
  • back-leakage measurement
  • Flow measurement

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 form. 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.

The Merlin S300-1 is a single unit designed to test both electro-hydraulic and piezo type injectors. Designed to operate Bosch, Delphi, Denso and Siemens common rail injectors.

Fault detection of injector short circuit, injector open circuit, incorrect injector type connected.

Supplied complete with electrical mains cable, connection cable with 4 adaptor cables to suit Bosch, Denso, Delphi, Piezo and general purpose applications.

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.

The Merlin C302 is a twin calibration unit for the measurement of fuel delivery and back-leak flow.

Merlin’s patented solenoid bottom fill/bottom drain system eliminates aeration and frothing of test oil normally caused by top fill systems. Instant reading and rapid drain systems give unit accuracy and efficiency. Supplied with 2 x 0-30cc glass tubes

*cabinet optional

 

DOWNLOAD SPECIFICATIONS

PRESSURE RANGE: 0-700 bar, psi, MPa or kgf/cm2
TIME RANGE: 0-99.9 seconds
PRESSURE: ±1 bar
TIMING: ±0.1% of full range
TRANSDUCER: ±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
CALIBRATION FLUID: Shell Calibration Fluid 4113, now S9365
INJECTOR EXITATION VOLTAGE: 85—135v dc
PULSE-WIDTH RANGE: 0.5—3.0ms
REPETITION RATE: 0.75 – 14Hz
FAULT DETECTION: Short circuit, open circuit.
METERING: 2 x 30cc calibrated tubes
Dimensions
HEIGHT:  780mm
LENGTH:  650mm
WIDTH:  1000mm
Installation details
ELECTRICAL SUPPLY: 240v/1 phase/50Hz
110v/1 phase/60Hz

 

 

S500-2R

S500-2R

The S500-2 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. Errors can be due to hysteresis in gauge readings, possible undetected mechanical damage, gauge inaccuracies and gauge needle bounce when setting nozzle opening pressure (NOP).

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

The S500-2/R retro-fit kit is supplied complete with 700 bar transducer and temperature probe and can be used with many types of injector tester.

On completion of a test where both NOP and back-leak pass, the results of the test are automatically sent to the serial printer port. A print-out of the last test, whether “pass or fail”, can be requested by pressing the push button when “print” is displayed on the screen.

Test parameters are programmable, stored and saved.

 

DOWNLOAD SPECIFICATIONS

PRESSURE RANGE: 0-700 bar, psi, MPa or kgf/cm²
TIME RANGE: 0-99.9 seconds
PRESSURE: ±1 bar
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
ELECTRICAL: 220/240v/1PH/50Hz
Dimensions
HEIGHT: 230mm
WEIGHT: 185mm
WIDTH: 540mm
WEIGHT: 10kg
S31

S31

The Merlin S31 is a 400 bar portable hand lever operated injector tester. Used for testing and adjusting conventional automotive 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.

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.

Left or Right handed operation.

DOWNLOAD SPECIFICATIONS

PRESSURE RANGE:  0-400 bar, psi (0-6000)
PRESSURE:  ±1 bar
PUMP OUTPUT:  1600/1800 mm³ per stroke.
DISPLAY:  Analogue Gauge
CALIBRATION FLUID:  Shell Calibration Fluid 4113, now S9365
THREAD SIZE:  M14 x 1.5
Dimensions
HEIGHT:  280mm
LENGTH: 460mm
WIDTH: 255mm
WEIGHT: 24kg
ADDITIONAL ADAPTORS:* T022-004 = M18 X 1.5
T022-003 = M18 x 1.5 split adaptor
T022-006 = 1/4″ BSP (Gardner Injectors)
T022-007 = 9/16″ x 18 UNF
T022-008 = 5/8″ x 18 UNF
T022-009 = M14 x 1.5 (long reach)
*Adaptors sold separately

 

S300-1

S300-1

The Merlin S300-1 is a single unit designed to test both electro-hydraulic and piezo common rail injectors. Designed and Developed with the following function:-

S300-1 Common Rail Injector System tester, one unit for the following systems:

  • Bosch
  • Delphi
  • Denso
  • Siemens (VDO)

The S300-1 can generate pulses suitable to drive piezo injectors as well as conventional solenoid types.

The duration of the pulse as well as the repetition rate can be adjusted to simulate a range of operating conditions.

When used in conjunction with a Merlin S400A or S425A air operated injector tester, a common rail injector can be operated sufficiently to observe the nozzle spray pattern and measure the backleak time. It can also be used with manually operated injector testers.

Fault detection:

  • Injector short circuit
  • Injector open circuit
  • Incorrect injector type connected

Supplied complete with electrical mains cable, connection cable with 4 adaptor cables to suit Bosch, Denso, Delphi, Siemens (VDO) Piezo and general purpose applications.

 

DOWNLOAD SPECIFICATIONS

INJECTOR EXCITATION VOLTAGE: 85v dc (Bosch/Delphi/Denso) 135v dc (Siemens)
PULSEWIDTH RANGE: 0.5-3.0ms
REPETITION RATE: 0.75-14Hz
FAULT DETECTION: Short circuit/open circuit
INJECTOR CURRENT: 25A
ELECTRICAL: 220-240v/110v
Dimensions
HEIGHT: 150mm
LENGTH: 210mm
WIDTH: 300mm
WEIGHT: 10kg
ADAPTOR CABLES: Delphi
Bosch
Seimens Piezo
Bosch Piezo
Bosh CRIN
NR3B NEEDLE GRINDER

NR3B NEEDLE GRINDER

The Merlin NR3B is an injector needle reconditioning machine capable of accurately grinding needle seat angles to manufacturer’s settings. It is suitable for reconditioning all types of nozzles ranging from automotive to rail, traction, generating and marine applications.

The following features are incorporated in the NR3B: –

  • Independent direct motor drive to work-head, there is no flexible drive.
  • Easily replaceable cartridge type extra precision grinding wheel spindle.
  • Operative angles 44° to 106°.
  • All handles grouped at front and side for ease of operation.
  • All moving parts are adjustable to ensure and maintain accuracy.

Optional cabinet is available, with ample storage space for laps, paste and equipment.

DOWNLOAD SPECIFICATIONS

CAPACITY: Nozzle valves, laps upto 25mm diameter & 250mm long. (Use optional oversize V-blocks for diameters in excess of 7mm)
OPERATIVE ANGLES 44° to 106° with attachments 14° to 136°
ACCURACY OF ANGLE: 1″ of included angle
GRINDING HEAD: Instantly replaceable cartridge type extra precision grinding wheel spindle
MOTOR: 1/3 hp (.25 Kw)
SPINDLE SPEED: 4000rpm
WORK SPINDLE SPEED: 150rpm
WORK-HEAD: Swivels through 180°. Rubber friction drive of needle valve, adjustable from spindle back plate. Slides and bearings are fully adjustable
ANGLE SETTING: Comprises V-block anvil mounting and dial gauge angle adjustment
CHUCK: 0-13.5mm capacity. (General purpose, e.g. nozzle lapping)
MAGNIFIER/LIGHT: Provides clear view of contact between the lap and grinding wheel