A5 Common Rail
A5 Common Rail
A5 Common Rail
INJECTOR REPAIR GENERAL TOOLS INJECTOR HOLDERS ARMATURE STROKE MEASURING KITS MISCELLANEOUS CLEANING TANKS AND TRAYS INJECTOR TESTING TEST ADAPTORS BACK-LEAK CONNECTORS HIGH PRESSURE CR TEST PIPES SHIM KITS PUMP REPAIR GENERAL TOOLS PUMP TESTING ADAPTORS DRIVE COUPLINGS PUMP MOUNTINGS FOR BOSCH TEST BENCHES PUMP MOUNTINGS FOR MERLIN/HARTRIDGE TEST BENCHES ENGINE TOOLS INJECTOR PULLERS GENERAL DELPHI DIAGNOSTIC EQUIPMENT COMMON RAIL TEST EQUIPMENT MERLIN S300-1 MERLIN MM815CR MERLIN S400A-CRC MERLIN S3000 MISCELLANEOUS CR ELECTRICAL CONNECTORS
1-2 2 3 4 4
5 6 6 7-8
9-11
12 13 13 14
15 16-17 17
18 19 19 20
21
Torx Sockets T021-937 10mm 0 986 613 632 T021-937a 12mm 0 986 613 631
T021-948 Injector Assembly Tool M27 0 986 613 613 Bosch CRI T021-948NG (same as above)
T021-952 Fibre Ring Insert Tool 0 986 613 640 Bosch CRI
Valve Seat Extractor T021-961 15mm 0 986 613 623 T021-962 17mm 0 986 613 626 Bosch CRI
INJECTOR HOLDERS
T021-019 Injector Holder 13, 15mm
T021-939 Shim Kit Idle Diameter 5.30 mm Hole 3.50 mm Range 1.20-1.70 mm Increments 0.05 mm T021-939X Shim Kit Idle Diameter 5.30 mm Hole 3.50 mm Range 1.40-1.86 mm Increments 0.02 mm T021-939V Shim Kit Idle Diameter 5.30 mm Hole 3.50 mm Range 0.90-1.90 mm Increments 0.05 mm
T021-940 Shim Kit Solenoid Diameter 4.50 mm Hole 2.50 mm Range 1.20-1.70 mm Increments 0.05 mm T021-940X Shim Kit Solenoid Diameter 4.50 mm Hole 2.50 mm Range 1.64-1.86 mm Increments 0.02 mm T021-940Y Shim Kit Diameter 4.20 mm Hole 2.30 mm Range 1.70-1.96 mm Increments 0.02 mm
T021-941 Shim Kit Solenoid Hexagonal Diameter 22.00 mm Hole 19.00 mm Range 1.00-1.01 mm Increments 0.01 mm RLS CRIN
T021-942 Shim Kit Solenoid Diameter 15.70 mm Hole 10.50 mm Range 1.20-1.30 mm Increments 0.01 mm Armature Stroke CR! 1, 2.0, 2.2
T021-943 Shim Kit, with flat Diameter 5.90 mm Range 8.40-8.50 mm Increments 0.01 mm
T021-944 Shim Kit Phase 2 Diameter 2.25 mm Range 1.14-1.25 mm Increments 0.01 mm Max. Fuel
T021-943X Shim Kit, with flat Diameter 5.90 mm Range 8.50-8.70 mm Increments 0.01 mm T021-943Y Shim Kit, round Diameter 5.70 mm Range 8.50-8.70 mm Increments 0.01 mm Max. Fuel
T021-954 Shim Kit Diameter 5.30 mm Hole 2.40 mm Range 1.72-1.90 mm Increments 0.02 mm
T021-955 Shim Kit Diameter 23.70 mm Hole 19.00 mm Range 0.90-1.00 mm Increments 0.01 mm T021-960 Shim Kit Diameter 23.70 mm Hole 19.00 mm Range 1.00-1.10 mm Increments 0.01 mm RLS CRI 2.1 Armature Stroke CRI 1, 2.0, 2.2
T021-966 Shim Kit Diameter hex Hole 17.00 mm Range 0.950-0.994 mm Increments 0.004mm Armature Stroek CRIN 1
T021-967 Shim Kit Diameter hex Hole 17.00 mm Range 0.998-1.042 mm Increments 0.004mm Armature Stroek CRIN 1
Tappet Lifters T016-675 0 986 612 427 T016-675L Ford 110 Duramax Bosch CP3
T016-677 Insert Tool Low Pressure Connection 0 986 612 200 Bosch CP1
T016-678 Insert Tool Low Pressure Connection 0 986 612 201 Iveco Bosch CP1
T016-679 Insert Tool Low Pressure Connection 0 986 612 205 Renault Bosch CP1
10
T016-680 Shaft Seal Inserter 0 986 612 422 Bosch CP1, CP3
T016-701 Socket for Inlet Connectors 0 986 612 991 Bosch CP3
11
T016-825 Mounting Mandrel for Gear Pump 0 986 611 665 Bosch CP1-H Use with T016-826
T016-826 Mounting Mandrel for Gear Pump 0 986 611 675 Bosch CP1-H Use with T016-825
T016-827 Assembly Tool for Return Valve 0 986 612 911 Bosch CP1-H T016-827NG Non-genuine version
T016-829 Filter Extractor Tool 0 986 613 153 Bosch CP1-H T016-829NG Non-genuine version
12
13
14
T012-305 Mounting Plate 68mm With 50mm insert. Universal including Delphi DFP1
T012-305-46 46mm insert for T012-305 T012-305-60 60mm insert for T012-305
15
16
T016-806 Pump Puller & Stroke Holding Tool Renault 2.2 dCi
T016-808 Timing Kit YDT202 Camshaft Bar & Engine Pin Ford Lynx
17
18
The MERLIN S300-1 is a single unit designed to test both electro-hydraulic and piezo type injectors. With common rail injectors the duration of the applied pulse along with the rail pressure determines the amount of fuel injected into the cylinder. The S300-1 can generate pulses suitable to drive piezo injectors as well as conventional solenoid types. Pulse duration and repetition rate are adjustable to simulate a range of operating conditions. The Merlin S300-1 is designed to operate Bosch, Delphi, Denso and Siemens series of automotive common rail injectors and, 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. No calibration required. Supplied complete with electrical mains cable, connection cable with 4 adaptor cables to suit Bosch, Denso, Delphi, Piezo and general purpose applications. Shipping details: L21 x W30 x H15cm Weight: 10kg
19
A range of common rail test equipment manufactured in the UK by Merlin Diesel Systems Ltd.
Suitable for testing:Bosch CP1, CP1H, CP1K, CP3, Delphi, Denso and Siemens systems. MM8-15CR Common Rail Test Stand Stand alone common rail test bench. Can also be used as a conventional test bench if required. Graduate Metering 15hp AC Inverter Drive S3000 specification same as retro-fit kit.
20
Drives up to four injectors Suitable for both piezo operated and electro-hydraulic injectors Suitable for SCV (e.g. Delphi) or PCV (e.g. Bosch) type DRV valves Auxiliary switched output (e.g. for third vane disable on certain pumps) Sequential injector drive, i.e. fuel delivery shots are timed as in a conventional mechanical pump Gives complete control of rail pressure, injector pulse width and pulse frequency via simple front panel controls Digital displays for injector pulse width and frequency, DRV valve drive percentage and rail pressure Automatic detection of short or open circuit injectors, as well as detection of the wrong type being connected Microprocessor based for extreme timing accuracy and having the ability to be controlled via a PC using the built in serial interface S3000 Standard equipment includes: Interlocked Safety Enclosure Merlin common rail assembly 2000 bar transducer Injector nozzle connectors Delphi Leak-o connections Test data with on-going updates CR Flexi HP Pipes CP3 Fuel Pump Pump mounting plate Mobile Cabinet Bosch Leak-o connections Range of adaptor cables
The Merlin S3000 Common Rail Retro-Fit kit can be mounted on various test benches such as Bosch 515, Hartridge 1100MK2 and the HA2500 as shown in this illustration.
Can be operated remotely via this control panel utility when installed on PC/Laptop.
21
Common Rail Repair & Test Catalogue DATA REF: MDS-TC-CR 0912
Manufacturers part numbers are given for reference purposes only and do not imply that in all cases the parts are of their manufacture. Illustrations and Technical Data are non-binding and are subject to change as a result of technological progress.
Merlin Diesel Systems Ltd 189-191, Bradkirk Place, Walton Summit Centre, Preston, Lancashire, PR5 8AJ, England Tel: +44 (0)1772 694180 Fax: +44 (0)1772 314565 Email: sales@merlindiesel.com www.merlindiesel.com