CarbonZAPP 2015 Product Brochure

The automotive industry has experienced remarkable change and
growth within the past years. In the automotive aftermarket servicing

sector, were following-up and guiding that change based largely on
our relentless view towards R&D leading to major improvements both
in functionality as well as efficient design. We are one of the global
leaders in Diesel and Gasoline Injector Service Stations and our products have become the standard that major OEs have integrated into
their recent range of equipment.
These advances and successes can also be attributed to our fundamental beliefs and priorities. Among those is the goal of including all
employees in the production process as thoroughly as possible to ensure a deep, thoughtful and broad knowledge of the products. This in
return nurtures respect and team work throughout the company.
Our belief is that successful companies are ones that satisfy their customers wants, market needs and desires. The data clearly show that
if your customer base is global and diverse and you reflect their perspectives and their knowledge, youre going to have a better chance for
success. This is especially true for CARBON ZAPP due to our extremely
diverse customer portfolio.
Nikolaos Pantazis
Dimitrios Pantazis
General Director
Manufacturing Director
01
contents
Carbon Zapp Company Profile
p. 03
Diesel injection systems
CRDi Solutions
p.08
EUI/EUP Solutions
p.14
HEUI Solutions
p.20
Test Bench Solutions
p.25
Diesel Repair Solutions
p.29
Common Rail Repair Tools
p.32
EUI/EUP Repair Tools
p.33
Gasoline Injection Systems
Direct Injection Solutions
p.36
Fuel Injection Solutions
p.41
Engine Diagnosis & Service
p.46
Extractors p.52
02
our company
Carbon Zapp is a leading manufacturer in Automotive Injection Service Equipment and Tools. Carbon Zapp operates today in 84 countries of the world and has
its headquarters and factory in Athens, Greece.
We are honored to serve our customers with quality products, state of the art
technology, and most importantly, our commitment to customer service. Carbon
Zapp has always believed that the purpose of our business was understanding
our customers needs and implementing it. Because we believe our customers
are truly our partners in attaining our goals, no request has been too small or too
large over past years. To support that idea, Carbon Zapp has, and will continue to
invest in our greatest plus, our people. Carbon Zapps staff is recognized by their
long tenure, training, certification and their individual and personal commitment
to one another and our customers. This single-minded focus on our customers,
and our obligation to a distinct plan, has created the basis for our success.
who we are
We have chosen to focus in manufacturing Automotive Injection Servicing Equipment, by offering only the highest quality products and service. Our objective is to
be recognized as the Company that provides the finest customer service, quality
products, technological innovations and experience in the field wherever we are
present, with a standard of professionalism second to none.
how we succeed
We succeed
by listening to our customers needs and requests
by giving always the best of ourselves
by engineering innovative technologies and providing solutions that become
norms in the Automotive Aftermarket Servicing
because we only present the best the market can offer in our range
because we have quality
because we are always there for our customers
how we behave
We express our beliefs in the way we treat each other and by the example we set
for one another. In all our cooperations with our customers, vendors, business
network and co-workers, we deal with others as we would expect them and want
them to deal with us.
our Customers
Automotive
Aftermarket OEs
Diesel Service
Centers
MAGNETI MARELLI
GB REMAN
ALFATEST
AEROSEC
LEITENBERGER
DIESELOGIC
and others
Auto Dealerships
Auto Workshops
Remanufacturers
Automotive OEs
PORSCHE
VAG
BOSCH
CONTI/VDO
DELPHI
03
our research team

In our Company, Innovation is the key to continuous growth and a competitive advantage. Carbon
Zapp promotes its research team to keep a high ambition level and continuously work on their research development and technical skills. On an annual basis, Carbon Zapp invests more than 35%
of its profits on research and development for upgrading existing products and for implementing
new products for the future. Carbon Zapp has built up an extensive group of intellectual property and
talented personnel throughout the years. Strategic agreements, world-class component suppliers
and manufacturers contribute in developing advanced technologies and products, and in conclusion
Carbon Zapp has achieved credibility and loyalty throughout its network. The objectives that have
been accomplished were made possible not only because of the research and development efforts, but also from the dedication and teamwork of Carbon Zapps committed staff.
recognized sales network

The key success reason in Carbon Zapps excellent collaborations with business partners and continuous ability to sustain a competitive edge is its globally integrated sales support capability. The
companys sales network today extends globally in all 5 continents and over 85 counties, which ensures that it delivers the best products and support corresponding to its customers needs. Our sales
markets are diverse and not limited to well stated economies. Our customer base is continuously
growing and strengthening, as our network is committed to our philosophy and products. We have
customers where todays technology begins, and also where technology is yet to come
customer service
Ever since Carbon Zapp was established, customer service and support were always a priority. In
the past 14 years, this field has shown significant progress in fulfilling goals and strategic decisions.
The assembly line was re-designed in order to increase output capacity and to simplify diagnosis,
service and repair of the equipment produced. Knowledgeable technical staff will answer the phone,
reply to an e-mail within 24-hours all year round. Carbon Zapp prides itself on a 1-hour average
response time to any problem or concern there may be.
We believe that we have earned our position because of our commitment to customer service;
service that emphasizes quality products and consistently prompt order handling and delivery. If
we fail to provide satisfaction to our customers, we forfeit our right to their business. Carbon Zapps
Management and staff loyalty to this business makes it a win-win situation says Mr. Bill Pantazis,
Owner and Founder of Carbon Zapp.
04
05
Diesel
Injection
Systems
Unique, compact, economic and professional
solutions for every workshop to test & service
diesel injection systems.
06
07
Di e s el i n j ect io n s y s t e m s
CRDi Solutions
Common Rail Revolutionary testing solutions for Bosch, Delphi,
Denso, Conti/VDO & more
systems
CR Piezo / Solenoid / Dual-Solenoid
CR Light Duty / Commercial
CR Heavy Duty / Industrial
CRU.4r
Test bench for 4 Common Rail
Diesel Injectors
Full-Automatic Operation
Diesel Expert level of Diagnosis
Injector Coding Capable2
Dynamic Electronic
Measurement (BK)
Under 25min testing phase
10 Touchscreen HMI
08
Extended Capabilities:
EUI / EUP with UIPr-A Attachment Unit
HEUI with HUIr-A Attachment Unit
CRU.2r
Test & Service bench for
1 Common Rail Diesel Injector
Diesel Expert level of Diagnosis
Injector Coding Capable2
Dynamic Electronic
Measurement (BK)
Under 8 min testing phase
10 Touchscreen HMI
DS2r-D
Advanced Workshop,
Dealer & Expert level
Static Electronic
Measurement (DFAP)
15 min testing phase
8 Touchscreen HMI
DS2r-A
Manual Operation
(user participation)
Workshop & Expert level
Analog Volumetric
Measurement (VT)
8 Touchscreen HMI
09
tests performed
characteristics
R2LC
Electrical test for k/F, /H
CFL
Check for Leaks test
LKT
Static Back leak test
aNOP
Automatic Nozzle Opening Pressure test
iVM (FL, PL, EM, LL, PI)
Injector Volume Measuring test (15-steps)
(full-load, part-load, emissions, low-load,
pre/post-injection tests)
iVM-MTS
Injector Volume Measuring test (multiple
test-points slope)
RSP
Injector Response time test
SPR
Dynamic Spray test performed in all testing
conditions
iPSC
Illuminated Pressurized spray chamber3 for clear
view of injected pattern up to 2500Bar. You can virtually see the multiple injections as happening in the
cylinder. Diagnosis of: NOP, incorrect spraying, leaky
or seized injectors.
The system integrates an easy and adjustable Injector
Clamp
RSP
RSP adapter1 is connected to the nozzle of each injector to precisely measure the actual mechanical
response time of injection from the electrical actuation signal. Diagnosis of: slow acting injector, retarded injection event, poor performance and emissions.
AZO Software
The revolutionary GUI that gives you the technological advancements of today. Wi-Fi printing & sharing,
server sync, auto-update of software and database,
wireless access and support and much more
Reports
Easy fail-track color report for each injector.
Quick view or Expert view reporting available.
10
iVM: injection volume metering

BK [electronic]:
Dynamic Injection Mass Metering (IVM)
CRU.2r / CRU.4r
Accurate, repeatable and fast electronic measurement of discharged and returned volumes. The
only Metering device available in the market today,
that has no moving parts, does not require filtering and temperature calibration. Shot-to-Shot and
Multiple-Injection-Metering Capability.
features
Dynamically measuring in mg/stroke

(equivalent to mm3/stroke)
repeatability: 0.05%, accuracy 0.2%
VT [manual]:
Graduated Tubes Injection Volume Metering (IVM)
DS2r-A
Precise, graduated and led illuminated tubes are
used for efficient diagnosis of uneven flow rates for
both discharged and returned volumes. Automatic
drainage after each test.
characteristics
resolution 0.5ml, accuracy 1ml/65ml

DFAP [electronic]:
Static Injection Mass Metering (IVM)
DS2r-D
Accurate and repeatable electronic measurement
of discharged and returned volumes. Has no moving parts, does not require filtering or temperature
calibration. A Carbon Zapp design (patent pending).
features
Statically measuring in mm3/stroke

resolution 0.1mm3, accuracy 0.6%
features
All Makes OE Manufacturer Database
User Programmable Database
HP up to 2500Bar1 with only 6.5Bar supply air
Piezo & Solenoid actuation (HV: 0-250 Volts / 0-35A)
Programmable Piezo profiles
Injector & PCB protection circuit (StG, StB, SC, OC, IC)
up to 18 Multiple Injections capable
Piezo return regulators1
Ergonomic, dynamic & robust design
aMACC Automatic chemical treatment and flushing of the injector
before testing1
Complementary set of CRi adapters, fittings and connectors for all
makes & types
User-friendly units
: Optionals
: Continuously updated function to more makes & systems
3
: Only 1 item is integrated per unit. Extra items are optional.
1
2
11
DSF.4r
Service & Flushing bench for
4 Common Rail Diesel Injectors
Semi-Automatic Operation
Advanced Workshop,
8 Touchscreen HMI
Every Diesel workshop that already has an Injector testing solution should be able with minimum cost
and effort to efficiently service and safely test diesel injectors. The DSF.4r unit along with the treatment
detergent will activate the inert carbon molecules, resins, varnishes and gums that accumulate inside
the diesel injector and flush them while operating the injector in different loads. For optimum cleaning
efficiency, the use of Carbon Zapps ultrasonic baths and detergents is recommended.
Dual Function System

Clean and Flush function performs cleaning of
the injector using a specially formulated treatment detergent and then automatically flushes
all injectors using new Calibration oil, preparing
them to be tested on any Test Bench safe and
clean.
features
Up to 1100Bar system
Adaptability to all
CRDi
Ergonomic,
12
Flushing Detergent
The Diesel Tech detergent activates the inert
carbon molecules, resins, dust varnish and
gums that accumulate inside the injector components, and filters them through the system.
The detergent used is safe for the user, harmless to all injector parts, Non-Flammable, NonCarcinogenic and friendly to the environment.
dynamic & robust

design
Spill free quickconnectors for
Discharge and
Return hoses
User-friendly units
extras
(optional)
adapters kit
A complete range of adapters1
for commercial vehicles, trucks,
buses and industrial engines are
available
ultrasonic device
UB15s
(42KHz, controlled Heater and

more)
UB15e
(42KHz or Sweep technology,

degas action, controlled Heater
and more)
NOTE: Ultrasonic Baths are
available upon order at sizes
up to 120L
portable stand
Modern design, compact and
lightweight with accessories
cabinet
ils and fluids

Diesel Injector
Calibration Oil
Diesel Treatment
Detergent
Ultrasonic Solvent
4L / 20L / 208L
2L / 25L
4L / 20L / 208L
13
EUI/EUP Solutions
E U I / E U P S R e v o l u t i o n a r y s i m u l a t o r f o r a l l M a k e s & Ty p e s .
Unit Injection Systems
Delphi E3, Delphi E1, DAF (Smart Pump/Injector), Scania/Cummins HPI,
Volvo (Bosch & Delphi), John Deere, Scania / Yanmar, Iveco, VW PDE
All CATs, Cummins Celect, Detroit Diesel, Cummins,
MB Actros, MB Atego, Mack, DAF, and more
UIPr-S
Test & Service Standalone bench
for 1 EUI/EUP Diesel Injector
Advanced Workshop,
Static Electronic
Measurement (DFAP)
Electronic & printed report
8 Touchscreen HMI
14
Servicing of unit injection systems is made easy not only for the Diesel
Specialists, but also for every workshop
application
passenger cars
heavy duty trucks
buses
marines
agriculture
industrial equipment
trains
UIPr-A
Test & Service Attachment bench
for 1 EUI/EUP Diesel Injector
Advanced Workshop,
Measurement and control done
via main unit DSr or CRUr series.
CRU.4r
working
with
CRU.2r
DS2r
15
tests performed
R2LC
CFL
RSP
Nozzle Opening Response time test1
BIP
Injector Control Valve Response time test1
SPR
conditions
characteristics
iPSC
Illuminated Pressurized spray chamber for clear view
of injected pattern. You can virtually see the multiple
injections as happening in the cylinder. Diagnosis of:
NOP, incorrect spraying, leaky or seized injectors.
Nozzle Clamp. Easy adjustable Cam stroke 4-20mm
with the use of adjustable wheel.
RSP
RSP & BIP adapters1 are connected to the nozzle and
the control valve of each injector to precisely measure the mechanical response time of the control
valve as well as the actual injection event. Diagnosis
of: slow acting injector, retarded injection event, poor
performance and emissions.
AZO Software
Reports
16

BK [electronic]:
UIPr-A
Accurate, repeatable and fast electronic measurement of discharged and returned volumes. The only
Metering device available in the market today, that
has no moving parts, does not require filtering and
temperature calibration. Shot-to-Shot and MultipleInjection-Metering Capability.
features

VT [manual]:
UIPr-A
characteristics

DFAP [electronic]:
UIPr-A / UIPr-S
features

features
All Makes Generic Database
All Makes Manufacturer Database2
Pneumatic operated unit (Test Bench NOT required)
Fast mounting and dismounting of injector/pump
Clear protective cover for injector/ pump
Low supply automatic pressure control (10Bar)
Dual-solenoid (E3 / DAF) control module2
Low Pressure dual supply system (Cummins)
Spill free quick-connectors for supply hoses
Low pressure fluid indication (0-10 Bar)
Simulation up to 1200Rpm (600 Strokes)
aMACC Automatic chemical treatment and flushing of the injector before testing1
User-friendly units
: Optionals
3
1
2
17
extras
(optional)
adapters kit
A wide range2 of UI/UP
adapters, fittings, adjusting rods
and electrical connectors for
most commonly used systems
of today are available1
ultrasonic device
UB15s

more)
UB15e

and more)
up to 120L
portable stand
cabinet
ils and fluids
18
Diesel Injector
Calibration Oil
Diesel Treatment
Detergent
Ultrasonic Solvent
4L / 20L / 208L
2L / 25L
4L / 20L / 208L
19
HEUI Solutions
T h e R e v o l u t i o n a r y H E U I s i m u l a t o r f o r a l l M a k e s & Ty p e s .
Hydraulic Unit Injection Systems
Caterpillar 3126, 7.3L,
Caterpillar C7/C9,
Navistar/ Ford Powerstroke 6.0L, 7.6L, 9.3L,
Isuzu Trooper
HUIr-S
Test & Service Standalone bench
for 1 HEUI Diesel Injector
up to 300Bar
Advanced Workshop,
Static Electronic
Measurement (DFAP)
Electronic & printed report
8 Touchscreen HMI
20
The accurate, cost-effective and compact solution for every workshop to

service Diesel HEUI injector systems.
application
light duty trucks
heavy duty trucks
HUIr-A
Test & Service Attachment bench
for 1 HEUI Diesel Injector
up to 300Bar
Advanced Workshop,
Measurement and control done
via main unit DSr or CRUr series.
CRU.4r
working
with
CRU.2r
DS2r
21
tests performed
R2LC
CFL
mNOP
Manual Nozzle Opening Pressure test
RSP
Nozzle Opening Response time test1
SPR
conditions
characteristics
iPSC
Illuminated Pressurized spray chamber for clear view
of injected pattern. You can virtually see the multiple
injections as happening in the cylinder. Diagnosis of:
NOP, incorrect spraying, leaky or seized injectors.
Nozzle Clamp.
RSP
RSP adapter1 is connected to the injector nozzle to
precisely measure the mechanical response delay
time of hydraulic actuator. Diagnosis of: slow acting
injector, retarded injection event, poor performance
and emissions.
AZO Software
Reports
22

BK [electronic]:
HUIr-A
Accurate, repeatable and fast electronic measurement of discharged and returned volumes. The only
Metering device available in the market today, that
has no moving parts, does not require filtering and
temperature calibration. Shot-to-Shot and MultipleInjection-Metering Capability.
features

VT [manual]:
HUIr-A
characteristics

DFAP [electronic]:
HUIr-A / HUIr-S
features

features
All Makes Generic Database
Pneumatic operated unit (Test Bench NOT required)
High pressure Hydraulic system control & indication (30-300 Bar / 40-4350 psi)
Fast mounting and dismounting of HEUI
Clear protective cover for injector
Low supply automatic pressure control (10Bar)
Dual-solenoid (Powerstroke) control module2
Low Pressure dual supply system (Cummins)
Spill free quick-connectors for supply hoses
Low pressure fluid indication (0-10 Bar)
aMACC Automatic chemical treatment and flushing of the injector before testing1
User-friendly units
: Optionals
3
1
2
23
extras
(optional)
adapters kit
A wide range2 of HEUI adapters,
fittings and electrical connectors for most commonly used
systems of today are available1
ultrasonic device
UB15s

more)
UB15e

and more)
up to 120L
portable stand
cabinet
ils and fluids
24
Diesel Injector
Calibration Oil
Diesel Treatment
Detergent
Ultrasonic Solvent
4L / 20L / 208L
2L / 25L
4L / 20L / 208L
Di e s e l i n j ect i o n s y s t e m s
Test Bench Solutions

Carbon Zapps Revolutionary TCCMr Simulator provides the capability for
every Conventional Test Bench out in the market to revive and test all makes
and types of CRDi, CRp, EUI/ EUP and HEUI systems.
TCCMr
Test Bench and Component Control
Module
Controls all types and makes of Components (injectors, pumps, control valves and more)
4 Injector Control Outputs, 4 RSP / BIP Sensor inputs, 4 Current Control Outputs and 15
programmable I/Os
Works with every Conventional Test Bench in the market
Connects to any Cambox (proximity triggered) and CRDi Simulator kit
Includes the most powerful and comprehensive CRDi database2 and test plans for Bosch,
Delphi, Denso, Conti/VDO and others.
A continuously updated wide-ranging EUI/EUP and HEUI database2 and test plans for all Makes
(Delphi E3, Delphi E1, DAF (Smart Pump/Injector), Scania/Cummins HPI, Volvo (Bosch & Delphi),
John Deere, Scania / Yanmar, Iveco, VW PDE, All CATs, Cummins Celect, Detroit Diesel,
Cummins, MB Actros, MB Atego, Mack, DAF, Caterpillar 3126 / 7.3L, Caterpillar C7/C9, Navistar/
Ford Powerstroke, Isuzu Trooper)
Powered by the AZO Software. The revolutionary GUI that gives you the technological
advancements of today. Wi-Fi printing & sharing, server sync, auto-update of software and
database, wireless access and support and much more
8 Touchscreen HMI
25
Testing Capabilities and Functions:

Component Electrical Condition (k/F, /H)
[R2LC]
HP and LP leakage
Excessive Return Overflow at Full Load [LKT]
Nozzle Opening Pressure [NOP]
CRDi Full Load, Part Load, Emissions, Low-Load,
Pre and Post Injection Volumetric Test
Points[iVM]
Mechanical Responsiveness of the injector
nozzle to the electrical signal [RSP]
EUI /EUP Control Valve Responsiveness test (BIP)
BIP / RSP evaluation analysis
Programmable Dual Coil Control (E3, DAF, etc)
EUI/ EUP, HEUI Max -Power, Max-Torque, Part
Load, Low-Load, Pre and Post Injection
Volumetric Test Points[iVM]
Spray quality and homogeneity in the
combustion chamber [SPR]
High pressure Control Valve operation
(DRV, IMV, PCV, etc...)
High Pressure Sensor reaction
High Pressure relief safety valve operation
Common Rail Pump Operation in different Test
Points (Full-Load, Part-Load, Low-Load,
and more)
CR Pump flow limiter valve operation
(ZME, IMV, SCV, VCV, etc...)
Piezo & Solenoid actuation
(HV: 0-250 Volts / 0-35A)
Injector & PCB protection circuit
(StG, StB, SC, OC, IC)
Optional Upgrades:
1. A dynamic, fast and accurate Electronic
Measurement [BK] Kit1.
Applications: CRDi, CRp, EUI/EUP, HEUI
2. A static, economic and precise Electronic
Measurement [DFAP] Kit1.
Applications: CRDi, EUI/EUP, HEUI
: Optionals
26
System Provided Solutions / Equipment
CRDi & CRp

CR Piezo / Solenoid /
Dual-Solenoid Injectors
CR Industrial / Commercial
Injectors
CR Heavy Duty Injectors
CRp (Common Rail Pumps)
EUI / EUP
HEUI
EUI / EUP
(Electronic Unit
Injectors / Pumps)
TBCR Kit
Complete Rail Kit with Bench base, parts,
components, connectors, HP & LP hoses and
more to test every possible CRDi system on
every Make Conventional Test Bench.
Adapters, connectors, fittings, RSP sensors
and more are available1.
HEUI (Hydraulic Electronic

Unit Injectors)
HUIr-A Unit. The fast , easy and
precise solution to test HEUIs
(Page 21)
Cambox
The Diesel Service Centers Proven Solution
a. Universal Cambox fits most Conventional
Test Benches (h:125mm)
b. Available adapters1 for all makes
and types
27
28
Di e s e l i n j ect i o n s y s t e m s
Diesel
Repair Solutions
Now servicing of All Makes2 Common Rail and UI/UPs is available
for every workshops easy and affordable.
29
The enormous growth of Diesel fleets, the stringent global emissions, the customer demands for fuel
economy, noise reduction and performance in accordance with bad fuel qualities are driving the market to
service Diesel Injectors as a regular periodic procedure.
Repair Diesel injectors to achieve:
Higher torque
Lower emissions
Improved fuel economy
Quieter performance
Clean, highly efficient fuel injection
Common Rail Injectors Repair Solutions

for all Makes & Types
Features
Workshop are now able to rebuilt Common Rail
injectors to OE specifications:
A remanufacturing method that includes the
latest OE specifications and product
improvements by Carbon Zapp in less than 15
Repair tolerances up to 1m
Cost-effective , efficient, reliable and
robust repair
New external O-rings, seals, caps and more
An environmentally friendly solution
Basic Repair:
Back-Leak High-Pressure Seal Repair / Nozzle
Replacement
1. Dismantling of all Components and cleaning
them using CZ Sweep Technology Ultrasonics
2. Replacement of Injector Nozzle if needed
3. Replacement of the high-pressure sealing
washer
4. Replacement or Resurfacing of the High
Pressure sphere / valve
5. iRVL Measurement & Adjustment using any
Carbon Zapp Test Bench
30
6. After Repairing, injectors have to be fully tested

on a Carbon Zapp Test Bench
Advanced Repair Solution [CRRS.01]:

Complete Injector Calibration / High-Pressure Seal replacement / Nozzle replacement
For the Diesel Workshop, our CRRS.01 repair solution is a significant jump in Common Rail service.
The solution allows for workshops to be able to remanufacture all types of CRi (N) injectors.
Standalone HMI & PC
Injector Measurement Vice
(15.6 touchscreen)
Electronic (Activation & COM) Module Kit
(with cables)
Calibration Base for Accurate
measurements (granite)
Injector Mounting/dismounting device
(with adjustment wheel)

Accurate electronic (4) micrometer
comparators Mitutoyo
Pneumatic Piston1 Press (CRi 2.1) (pic: a)
or Mechanical Screw Press (CRi 2.1) (pic: b)
Electronic Torque Wrench1
1. Dismantling of all Components and cleaning
them using CZ Sweep Technology Ultrasonics.
2. Replacement of Injector Nozzle if needed
3. Replacement of the high-pressure sealing
washer
4. Replacement or Resurfacing of the High
Pressure sphere / valve
5. Calibration of all operational parameters
a. residual air gap
b. nozzle needle lift
c. nozzle spring strength
d. armature (valve) lift
e. valve spring strength
f. extra lift
6. Replacement if needed/applicable of the
electrical actuator
7. After Repairing, injectors have to be fully
tested on a Carbon Zapp Test Bench.
All sizes shims and

spare parts to repair and
calibrate Bosch common
rail injectors are available
A big variety of shims
and spare parts to repair
and calibrate Denso, Delphi & VDO Common Rail
injectors are available
31
Common Rail Repair Tools
32
DiT-062
GV3-352CR
Diesel injector manual hand pump

tester
0-600bars
Advanced universal tool to dismount & mount all type of nozzle

holders [CRDi] of all DI makes
SRA-061CR
SRA-129CR
Universal Complete Tool kit to

disassemble and repair Common
Rail Injectors [Bosch and others]
Universal Adjustable Clamp Plate

for vice to hold injectors upright
and service.
Applicable to all type of injectors
SRA-370
SRA-440
Universal Injector Seat (engine cylinder head) cleaning for BOSCH,

DELPHI, DENSO, CONTI/VDO
Tools Kit to extract and replace the

fiber ring on the control spool valve
of the BOSCH CR injectors
(components: Puller, Inserter,
Positioning device)
SRA-400
SRA-491
Lapping tool kit for CR Injector

Control Valve Spherical seat (Is
used to recondition the conic seat
of the closing valve (CR return
valve) positioned under the CR
injector solenoids)
Nozzle holder cap wrench for

DELPHI injectors
models: FORD Mondeo Transit,
and others..
SRA-500
SRA-501
CRDi Solenoid wrench

Dismounting Wrench for
solenoid HEX. 29mm
CRDi Solenoid wrench

Dismounting Wrench for
solenoid HEX. 30mm
SRA-503
SRA-050
Illuminated lens with X10 magnification, led operated
Anti-magnetic pliers kit for injector control valves, shims, spheres

and other parts replacement
EUI/EUP Repair Tools

SRA0313-CR
SRA0134-00
Advanced Universal Tool to dismount and mount all types of

Diesel Injections Systems [CRDi,
EUI, EUP, PLD and PDE]
Swivel vice for dismounting plate
SRA0313-CELL1
Load Cell for pick-up Force (with
digital indicator)
SRA0127-00
SRA0055-01
Dismounting plate for UI/UP: 28,2

mm - 32,50 mm - 39,50 mm
Diamond tool for lapping valve

hole (cylinder)
SRA0055-00
SRA0055-02
Diamond tool for lapping valve

seat
Kit to measure the diameter of the

valve seat
(to be used before mounting a new
valve)
SRA0004-03
SRA0501-CR32
Test adaptor - thread 31x1mm
Open wrench diam. 32mm
SRA0495-00
SRA0483-GR
Solenoid Octagonal Wrench 38mm
Wrench diameter: 10mm with

internal hole: 8,50mm
SRA007-19MIL
EUI / EUP SPARE PARTS
Micrometer
A variety of spare parts for all EUI

/ EUP systems is offered. Separate
parts list is available
33
Gasoline
Injection
Systems
The only professional solutions for Remanufacturers
and workshops to test & service Gasoline injection
systems.
34
35
Gasoline injection systems
Direct
Injection Solutions
Gasoline direct injection requires high pressure testing to truly diagnose
operation faults. Carbon Zapp once again provides the only complete testing solution in the market today, with the Revolutionary GDU.4r, GDU.2r
and GD1r Test benches.
systems
Bosch, Conti/VDO, Delphi, HTC and others
G-DI / FSI / HPI / DISI / SIDI etc..
GDU.4r
Test bench for 4 Gasoline Direct
Injectors
HP up to 550Bar
Gasoline Expert level of
Diagnosis & dealerships
Dynamic Electronic
Measurement (BK)
10 Touchscreen HMI
36
Piezo and Solenoid injectors

Up to 550Bar+
GDU.2r
1 Gasoline Direct Injector
HP up to 550Bar
Gasoline Expert level of
Diagnosis & dealerships
Dynamic Electronic
Measurement (BK)
Under 5 min testing phase
10 Touchscreen HMI
GD1r-D
HP up to 300Bar
Advanced Workshop,
Dealership & Expert level
Static Electronic
Measurement (DFAP)
8 Touchscreen HMI
GD1r-A
Manual Operation
(user participation)
HP up to 300Bar
Workshop & Expert level
Analog Volumetric
Measurement (VT)
7 min testing phase
8 Touchscreen HMI
37
tests performed
R2LC
CFL
LKT
Static High Operating Pressure Leak test
RSP
Injector Response time test
SPR
conditions
characteristics
iPSC
Illuminated Pressurized spray chamber3 for clear
view of injected pattern up to 550Bar. You can virtually
see the complete injection pattern as happening in the
cylinder. Diagnosis of: NOP, incorrect spraying, leaky
or seized injectors.
Clamp
RSP
RSP adapter1 is connected to the nozzle of each injector to precisely measure the actual mechanical response time of injection from the electrical actuation
signal. Diagnosis of: slow acting injector, retarded
injection event, poor performance and emissions..
AZO Software
Reports
38

BK [electronic]:
GDU.2r / GDU.4r
Accurate, repeatable and fast electronic measurement of discharged volumes. The only Metering
device available in the market today, that has no
moving parts, does not require filtering and temperature calibration. Shot-to-Shot and MultipleInjection-Metering Capability.
features

VT [manual]:
GD1r-A
used for efficient diagnosis of uneven flow rates
of discharged volumes. Automatic drainage after
each test.
characteristics

DFAP [electronic]:
GD1r-D
of discharged volumes. Has no moving parts,
does not require filtering or temperature calibration. A Carbon Zapp design (patent pending).
features

features
HP up to 550Bar1
Piezo & Solenoid actuation
(HV: 0-250 Volts / 0-35A)

Injector & PCB protection circuit
(StG, StB, SC, OC, IC)
Multiple Injections capable

aMACC Automatic chemical treatment
and flushing of the injector before testing1

Complementary set of GDi adapters, fittings
and connectors for all makes & types
User-friendly units
: Optionals
3
1
2
39
extras
(optional)
adapters kit
A complete range of adapters2
for All Makes and Types Gasoline
Direct Injectors is provided.
tools
SRC-505
Gasoline injector screen

filter extractor tool
GV3-4100
Injector puller kit suitable for

gasoline direct injection engines
(VAG-FSI and others)
ultrasonic device
UB15s

more)
UB15e

and more)
up to 120L
portable stand
cabinet
ils and fluids
40
Gasoline Injector
Calibration Oil
Gasoline Treatment
Detergent
Ultrasonic Solvent
4L / 20L / 208L
2L / 25L
4L / 20L / 208L
Gasoline injection systems
Fuel Injection
Solutions
The efficient, cost-effective and proven workshop solution to bench
test and service every fuel injector.
GS8
GS4
GS2
systems
G-DI / FSI / HPI / DISI / SIDI (Direct injection),
MPFI /SPFI, L-JETRONIC (Multi-port fuel injection)
CSFI, CPFI (Central port injection)
TBI / CFI (Throttle body injection),
K-JETRONIC (Continuous Injection),
MARINES, E-TEC / FICHT
Other:
Motorcycles, LPG, Alternative fuels
41
service & repair

Increased exhaust emissions
Reduced engine performance (Power, Torque)
Increased fuel consumption
Poor drive-ability situations
Direct injection systems failure (Leaks, Pressure drop)
Rough idle and periodic stall of the engine
Conditions that lead to long-term catalytic converter damage
Extended engine start-up
MIL - check engine light-up

Precise, Graduated and led illuminated tubes are used for efficient
diagnosis of uneven flow rates and weak or defective nozzle springs
at operating pressures. Automatic drainage after each test.
features
resolution 1ml, accuracy 1ml/130ml
features
Operating Pressure 0-10 Bars
Gasoline Direct Injectors tested up to 10 Bar
High Battery Peak A and battery hold A control
fully programmable
Variable & Customizable Test-Plans
Engine load Simulation Tests
Manufacturer / User Injector Database2
Ergonomic and dynamic and user-friendly design
Short testing time required / Automatic function
Ergonomic, robust, fast & simple injector clamping
Spray and Volume test
Injector Protection circuit
Injector Reverse flush after U/Sonic cleaning
Language Localization
: Optionals
3
1
2
42
GS8
GS4
GS2
43
adapters
Standard Kit
Set of Fuel Rail & Adapters
for all makes and types of
Top-Feed and G-DI Injectors [4]
TBI Kit
Set of Fuel Rail & Adapters
for all makes and types of
throttle body and Side-Feed
injector [1]
Exclusive Kit
Complete set of Fuel Rail &
Adapters, special designed
for easy and fast adaptation
to all makes and types of
Top-Feed, G-Di, Side-Feed
Injectors. [4]
E-TEC Kit
Complete Rail Kit specially
designed for easy and fast
adaptation E-TEC / FiCHT
Injectors. [4]
44
extras
(optional)
tools
SRC-505
Gasoline injector screen

filter extractor tool
GV3-4100
Injector puller kit suitable for

gasoline direct injection engines
(VAG-FSI and others)
ultrasonic device
UB15s

more)
UB15e

and more)
up to 120L
portable stand
cabinet
ils and fluids

Gasoline Injector
Calibration Oil
Ultrasonic Solvent
4L / 20L / 208L
4L / 20L / 208L
45
Engine
Diagnosis &
Service
Modern engine servicing, calls for time-saving,
easy-to-use and cost-effective solutions.
46
47
ES series
Diesel & Gasoline Engine Treatment Unit
ES-10 / ES-20
motorcycle
passenger cars
light duty trucks
heavy duty trucks
buses
marines
ES-60
marines
agriculture
ES-120
trains
systems
Common-Rail and
Conventional Diesel
Gasoline Direct Injection
(G-DI, FSI, HPI, etc.)
Conventional Fuel Injection
(MPFI / TBI / CIS)
LPG / CNG and
Alternative fuels Carburated
adapters
Fuel system adapters kit
48
DPF.01
detergent
The ENGINE TECH detergent activates the inert carbon molecules,
resins, dust varnish and gums that accumulate inside the engine
components, and burns them with the combustion process.
Safe for the user

Harmless to all engine parts
Non-Flammable
Non-Carcinogenic product and
friendly to the environment
Efficient to all types of engines.
IMC.01
features
Dual-Tank system (ES-20)
Automatic Pressure adjustment
Adaptability to all makes and models
Intake manifold cleaning with adapter unit1 (IMC.01)
Diesel Particulate Filter cleaning with adapter unit1 (DPF.01)
Automatic /manual functions
On-Display guide with language localization
Upgradeable & User-friendly
Portable, Lightweight and Robust product
benefits
Exhaust emissions reduction more than 70%
Maximum restoration of engines performance
Reduction of fuel consumption
Common-Rail system cleaning
High Pressure pump conditioning
De-carbonization of the combustion chamber
De-carbonizing of Intake Manifold and throttle body
Optimum fuel combustion
Blocked valves and piston rings release
De-carbonization of the catalytic converter & DPF
Improved idle-speed stability
Fading of engine knocking
Prevention of long term expensive repairs
Technical Specifications
Fuel Tank Capacity (Lt) (Option to customize Lt size)
Fuel Supply Capacity (Lt/ H Gal/H)
Gasoline / Diesel Fuel Filter (m)
Fuel Feed / Fuel Return Hoses
12V Power Cable
Fuel Pressure Gauge (Gasoline / Diesel)
Automatic adjustment to system operating pressure
Input power (Volts) / Max Power Consumption (Watt)
Packaged Dimensions WxDxH (cm) / Weight (Kg)
Dimensions and weight values are subject to change
without notice
ES-10
ES-20
ES-60
ES-120 + Portable Tank
[ Common tank ]
5
200
8
(2) 3m / 10ft
3m / 10ft
0-10 Bar / 0-150Psi
YES
12 VDc / 100W
62 X 48 X 98 / 42
[ Dual tank ]
5 / 3.5
200
8/8
(4) 3m / 10ft
3m / 10ft
0-10 Bar / 0-150Psi
YES
12 VDc / 100W
62 X 48 X 98 / 46
[ Common tank ]
10
600
10
(2) 3m / 10ft
3m / 10ft
0-10 Bar / 0-150Psi
NO
12 VDc / 280W
62 X 48 X 98 / 60
[ Separate tank ]
92
1200
10
(2) 3m / 10ft
3m / 10ft
0-10 Bar / 0-150Psi
NO
12 VDc /650W
ES-120: 65 X 50 X 100 / 70
PT-92: 60 X 50 X 100 / 48
49
FST / FST-HF
Diesel & Gasoline
Fuel System Tester
diagnosis
application (systems)
CRDi / DI / G-Di / MPFI / TBI / CIS
Incorrect fuel pressure

Incorrect system fuel
flow
Plugged fuel filter
Faulty fuel pump
Plugged fuel pump inlet
strainer
Faulty fuel pump check
valve
Leaky fuel injectors
Incorrect operation of the
fuel pressure regulator
Fuel foaming and/or
contamination
Restrictions in supply/
return fuel lines
Intake manifold vacuum
fluctuation
Exhaust back-pressure
for testing DPF &
Catalytic Converter
Turbo-boost pressure
operation
features
Compact, Portable and Robust

for use in the workshop
High flow capability for Racing and
performance applications (FST-HF)
Easy readable analog gauges:
Fuel Pressure, Manifold Vacuum,
Exhaust Back Pressure
Durable clear flow tube
Quick & safe connectors
Easy hook for mounting on engine
hood
Adaptability for all makes and
models
adapters
Fuel system adapters kit

(as ES Series page 48)
FST
FST-HF
Fuel Pressure Gauge

0-100 Psi / 0-7 Bar
0-100 Psi / 0-7 Bar
Manifold Vacuum Gauge
0-30 inHg / 0-100 KPa vacuum
0-30 inHg / 0-100 KPa vacuum
Exhaust Backpressure Gauge
0-15 Psi / 0-100 KPa
0-15 Psi / 0-100 KPa
Scaled Fuel Flow Tube
0.3 3.3 Lt/min // 0.1 0.87 gal/min 0.6 6.6 Lt/min // 0.2 1.75 gal/min
Case Dimensions WxDxH (cm) / Weight (Kg)
53 X 43 X 14 / 5.3
53 X 43 X 14 / 5
Dimensions and weight values are subject to change without notice
HP-G2500
Common Rail Injection - Fuel System Tester
HP-G250
Diesel / G-DI - Fuel System Tester
diagnosis
CRDi [HP-G2500]
G-Di / DI [HP-G250]
Incorrect fuel pressure

Faulty fuel pump
Faulty fuel pump check valve
HP Pump response
System Leaks
Faulty Pressure Sensor
Leaky fuel injectors
Extends the FST tool
diagnosis
features
Compact & Portable

Dynamic & Static tests
Easy readable analog gauge for
High System Pressure
Robust for the work-shop
Live Rail pressure readings
Adaptability for all Injection
Systems
50
Fuel Pressure Gauge with glycerin

High Pressure Flexible Lines (2pcs)/Dimensions
Low Pressure Relief Line / Dimensions
Case Dimensions WxDxH (cm) / Weight (Kg)
HP-G250
HP-G2500
0-3600Psi / 0-250 Bar

20000Psi / 1400Bar / 70cm
145Psi / 10Bar / 50cm
53 X 43 X 14 / 5
0-36000Psi / 0-2500 Bar

65000Psi / 4500Bar / 70cm
------53 X 43 X 14 / 8
Dimensions and weight values are subject to change without notice
CRPT-110
Digital Common Rail Pressure Tester
CRMK-110
features
diagnosis
Easy Operation / Robust design

Adaptability to All Makes sensors
Operation Range
0..1500 bar or 0.2000 bar
Measurement resolution of 1 bar
Indication for defective pressure
sensor
Fault detection indicated by a red
warning LED
Automatic shut-off after 1 minute
Power supply by 9 V battery
(standalone unit)
CRDi system operating

pressure
CRDi system leaking
Common Rail Backflow Kit for All

Injector Makes
Test kit for checking the return flow
volumes from Common-Rail
Systems
Plexiglass robust container
with graduated scales for easy
comparison
Metal chain hook to hold tester in
upright position of the engine hood
Full set of adapters to connect to
the Injectors return port
BOSCH, CONTI/ VDO, DELPHI

and DENSO Common Rail
Systems
features
Transparent plexiglass tester to

permit view of any air pockets
which may be present in the fuel
Interchangeable vacuum gauge on
the test unit for further testing
capabilities
Adaptability for most injectors in
the market
Pressure relief valve for safe
removing from engine
BOSCH: -1 to +15 Bar gauge

CONTI/ VDO, DELPHI &
DENSO: -1 to +3 Bar gauge
PIMK-010
Piezo CRDI Backflow Pressure Tester
diagnosis
Piezo CRDi return pressure
Common-Rail injector
proper operation
SRA-342CR
Common Rail Backflow Kit for All
Injector Makes
Basic testing kit for measuring
overflow of CRDi
Holder for all injector high flow
tubes
Individual tubes for injector
backleak port
Full set of adapters to connect
to the Injectors return port
BOSCH, CONTI/ VDO, DELPHI

and DENSO
51
Extractors
Extractors for Common Rail injectors for professional mechanics, car-repair garages or workshops
52
GV3-0260
GV3-0320
Universal complete set suitable for

removing Bosch & Delphi CRDi
models: MERCEDES, VOLVO, FORD,
RENAULT, KIA, Trucks and General injectors
Extractor specific for MERCEDES

injectors including socket for dismounting the electrical connection
CDI models: MERCEDES
Sprinter Vito Viano Vario, etc..
GV3-8400
GV3-8500
Universal kit for All Makes injector

removal, with two distinct procedures:
i) the pliers with holding arms
ii) or the use of the articulated joint
adapter and the pivot
Universal kit for CRDi removal.

Allows working safely and efficiently on removed engine using a
slide hammer.
Systems: BOSCH, CONTI/VDO,
DELPHI
GV3-7903
GV3-0640
DELPHI EMBR (Piezo & Solenoid)

Extractor extension with adapter
M18X1,5-M12. Slide hammer is
Not supplied.
models: Mercedes OM651, DFI 1.5
DELPHI (EURO 5), and others..
DELPHI Injectors extractor

[EJBR, EJDR]
models: SSANGYONG,
MERCEDES, MAZDA, KIA and
others..
GV3-0760
GV3-4400
Copper Seal-Ring Extractor. Can

remove seized copper sealing
rings without damaging the cylinder head. Equipped with a slide
hammer for ease of operation.
Copper Seal-Ring Extractor for

Trucks. Can remove seized copper
sealing rings without damaging
the cylinder head. Equipped with
a slide hammer for ease of operation.
GV3-6601
GV3-2200
Universal complete set suitable

for removing All Makes CRDis.
Specific for disassembling very
locked injectors in restricted positions [mechanical operation]
(GV3-2200 Cylinder Not Supplied) 1
Mechanical-Hydraulic cylinder:
12tons-stroke 8mm. Compact size
allows its application directly on
the vehicle, therefore it is not necessary to remove the engine.
[Works with GV3-6601
GV3-6900
GV3-2700
Complete set for removing all

types DENSO injectors. Equipped
with hammer.
models: TOYOTA, NISSAN, MAZDA,
OPEL/VAUHXALL, LEXUS and others..
Universal injector seat cleaner and

milling kit. Kit to be used for removing the combustion residues
that remain in the Injectors Seat
without any damages.
photo: George Tzortzis

kalma.design@gmail.com
364 Varis - Koropiou Ave.
tel
19400 - Attiki, Greece
fax +30
+30 210 9928304

210 9928655
info@CarbonZapp.com
www.CarbonZapp.com

CarbonZAPP 2015 Product Brochure

Caricato da

Informazioni sul documento

Descrizione originale:

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

CarbonZAPP 2015 Product Brochure

Caricato da

Copyright:

Formati disponibili

The automotive industry has experienced remarkable change and

growth within the past years. In the automotive aftermarket servicing

Diesel injection systems

Test Bench Solutions

Diesel Repair Solutions

Common Rail Repair Tools

EUI/EUP Repair Tools

Gasoline Injection Systems

Direct Injection Solutions

Fuel Injection Solutions

Engine Diagnosis & Service

our research team

recognized sales network

iVM: injection volume metering

Dynamically measuring in mg/stroke

resolution 0.5ml, accuracy 1ml/65ml

Statically measuring in mm3/stroke

Dual Function System

dynamic & robust

(42KHz, controlled Heater and

(42KHz or Sweep technology,

ils and fluids

iVM: injection volume metering

Dynamically measuring in mg/stroke

resolution 0.5ml, accuracy 1ml/65ml

Statically measuring in mm3/stroke

(42KHz, controlled Heater and

(42KHz or Sweep technology,

ils and fluids

The accurate, cost-effective and compact solution for every workshop to

iVM: injection volume metering

Dynamically measuring in mg/stroke

resolution 0.5ml, accuracy 1ml/65ml

Statically measuring in mm3/stroke

(42KHz, controlled Heater and

(42KHz or Sweep technology,

ils and fluids

Test Bench Solutions

Testing Capabilities and Functions:

System Provided Solutions / Equipment

CRDi & CRp

HEUI (Hydraulic Electronic

Common Rail Injectors Repair Solutions

6. After Repairing, injectors have to be fully tested

Advanced Repair Solution [CRRS.01]:

Standalone HMI & PC

Injector Measurement Vice

(with adjustment wheel)

All sizes shims and

Common Rail Repair Tools

Diesel injector manual hand pump

Advanced universal tool to dismount & mount all type of nozzle

Universal Complete Tool kit to

Universal Adjustable Clamp Plate

Universal Injector Seat (engine cylinder head) cleaning for BOSCH,

Tools Kit to extract and replace the

Lapping tool kit for CR Injector

Nozzle holder cap wrench for

CRDi Solenoid wrench

CRDi Solenoid wrench

Illuminated lens with X10 magnification, led operated

Anti-magnetic pliers kit for injector control valves, shims, spheres

EUI/EUP Repair Tools