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Stardex 0304 Manual

Common rail injectors tester
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HELSINKI, FINLAND, 2015
COMMON RAIL INJECTORS TESTER
STARDEX® 0304

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Summary of Contents for Stardex 0304

  • Page 1 HELSINKI, FINLAND, 2015 COMMON RAIL INJECTORS TESTER STARDEX® 0304...
  • Page 2 Safety rules for working with STARDEX 0304 device. Before using the device STARDEX 0304 (further “the device”) read this manual carefully. The device should be plugged only in a circuit of alternative current, mentioned in the passport of the device. In order to power up the device, use only supply cable from the delivery kit.
  • Page 3 Specifications and operation directions Dimensions 450х400х200 mm AC power supply 220V 50Hz or 110V 60Hz Power consumption in stand-by mode Power consumption in load mode 400W Operating temperature From -10 С to + 50 С Relative air humidity not more than 90% at 25 С...
  • Page 4 Linux, allowing you to connect a keyboard, mouse, printer and monitor directly to STARDEX 0304.  STARDEX 0304, combined with a hand pump, enables to make an express test of Common Rail injectors on the following parameters: efficiency, leakage, quality of injection, pressure at the beginning of the injection, state of electromagnetic coil (solenoid) or piezoelement of injector.
  • Page 5 Connectors and control buttons. ① Power cable connector. ② Power switch. ③ RPM sensor connector. ④ Pressure sensor connector. ⑤ Injector cable connector. ⑥ Regulator connector 1. ⑦ Regulator connector 2. ⑧ Regulator connector 3. ⑨ USB ports. ⑩ Output for external display.
  • Page 6 ① Front panel light diode Has 3 states:  No light – the device is de-energized.  Red light – standby mode.  Green light – the device is on. ② On/off button.

  • Page 7: Switching On / Off The Device

    Switching on / off the device. Fix the AC power switch 230V – 115V in the needed position. Plug in the device, using the power cable from the supply kit which must be attached to the power cable connector. Connect mouse, keyboard, printer and LCD monitor to appropriate connectors on the back panel of the device.

  • Page 8: Main Menu

    Main menu. After switching on and loading the device, the main menu is shown on the display, where the user can choose the mode of the device. ① HAND PUMP is a mode for testing mechanical and common rail injectors with the hand pump.
  • Page 9 HAND PUMP (MAIN > HAND PUMP) After going to HAND PUMP, the hand pump mode menu will be displayed. ① COMMON RAIL – testing of Common Rail injectors on the hand pump (express test). ② MECHANICAL – testing of usual mechanical injectors on the hand pump. ③...
  • Page 10 High pressure pump bench (MAIN > TEST BENCH) After going to TEST BENCH, the high pressure pump bench menu will be shown on the display. ① INJECTORS – testing of common rail injectors on the high pressure pump bench in hand or semi-automatic mode.
  • Page 11 Testing of common rail injectors on the hand pump (MAIN > HAND PUMP > COMMON RAIL) After going to the common rail injector test mode on the hand mode, the selection of injector types will be displayed on the screen. ①...
  • Page 12 After selecting the type of the injector, the express test window will open. ① Type of tested injector. ② Pre-installed pulse mode – beforehand installed pulse characteristics for an injector (width, frequency).  Minimal – 500 microseconds 20Hz.  Low – 800 microseconds 20 Hz. ...
  • Page 13 Connect the fuel rail pressure sensor for testing one injector installed on the hand pump to the pressure sensor connector. Switch on STARDEX 0304 and follow MAIN > HAND PUMP > COMMON RAIL. Select the type of the injector tested. Select pulse width and frequency.
  • Page 14 Delphi, Piezo Bosch, Siemens Common Rail injectors have the following gradation of leakage:  From -5 to -1 critically bad  From -1 to 0 relatively bad  From 0 to 1 relatively operational  From 1 to 3 good ...
  • Page 15 Testing of mechanical injectors on the hand pump (MAIN > HAND PUMP > MECHANICAL) After going to MECHANICAL, the window for selecting a serial number will open. ① Filter is a line for inputting a part of a serial number to simplify search in the data base. Data base records which do not contain the inserted part of the number will be automatically removed from the screen.
  • Page 16 Connect the fuel rail pressure sensor for testing one injector installed on the hand pump to the pressure sensor connector by the cable from the kit. Switch on STARDEX 0304 and follow to MAIN > HAND PUMP > MECHANICAL. Choose the serial number of the injector or the nozzle.
  • Page 17 To get accurate value of opening injector pressure the handle of the hand pump must be moved several times! Testing of Common Rail injectors on the high pressure pump bench (MAIN > TEST BENCH > INJECTORS) After following to INJECTORS, the window for selecting the test mode will open. ①...
  • Page 18 After going to TESTPLAN, the window for selecting the type of common rail injectors will open. ① BOSCH – electromagnetic injectors Bosch. ② DELPHI – electromagnetic injectors Delphi. ③ DENSO – electromagnetic injectors Denso. ④ SIEMENS – piezoelectric injectors Siemens. ⑤...
  • Page 19 After choosing the manufacturer, the window for selecting injector serial number will open. ① Filter is a line for inputting a part of a serial number to simplify search in the data base. Data base records, which do not contain the inserted part of the number, will be automatically removed from the screen.
  • Page 20 After selecting injector serial number, the window for testing Common Rail injectors on the high pressure pump bench will open. ① Information line is a line where manufacturer and serial number of tested injectors are shown. ② Test step shows the name of the current testing mode, the horizontal arrows change modes.
  • Page 21 ⑨ RPM – real revolutions of the pump measured by RPM sensor (optionally included in STARDEX 0304 delivery kit). A user sets the value of revolutions by himself, according to the conditions of the test specified in the information area.
  • Page 22 STARDEX 0104). Connect the fuel rail pressure sensor to the appropriate channel of STARDEX 0304 and connect the fuel rail pressure regulator to the first channel of STARDEX 0304, using wires from the kit. Connect STARDEX 0304 with the proper six-injector cable from the kit to injectors.
  • Page 23 Typical connection diagram. Testing of Common Rail pump on the high pressure pump bench (MAIN > TEST BENCH > PUMPS) After going to PUMPS, the window for the test mode selection will open.
  • Page 24 ① Manual is a manual mode for testing the pump on the high pressure pump bench. ② Testplan is a semi-automatic pump testing mode on testplan. ③ Quit to menu TEST BENCH. After going to TESTPLAN, the window for selecting manufacturer will open. ①...
  • Page 25 After choosing manufacturer, the window for selecting serial number will open. ① Filter is a line for inputting a part of a serial number to simplify search in the data base. Data base records, which do not contain the inserted part of the number, will be automatically removed from the screen.
  • Page 26 ① Information line is a line where manufacturer and serial number of tested injectors are shown. ② Test step shows the name of the current testing mode, horizontal arrows change modes. ③ Field of information is an opening list, where the mode of the current test step is described.
  • Page 27 1 using appropriate wires from the kit. Connect pump pressure regulators (if exist) to the regulator connectors 2, 3. Turn on STARDEX 0304 and follow MAIN > TEST BENCH > PUMPS. Select manufacturer and serial number of the tested pump. Follow step- by-step instructions in the information field.

  • Page 28: Additional Menu

    Additional menu There are additional menus in the right part of the screen. Additional menus can vary depending on test mode or other connected STARDEX devices. Current graph ① Return – go back to the previous window. ② Current scale – intensity of current in the injector circuit measured in Ampere.
  • Page 29 Settings ① Display resolution sets resolution of an external monitor. ② Pressure sensor type is set according to the type of the pressure sensor connected to the device. It has 2 values:  1500 bar  1800 bar ③ Injector delivery measuring units sets used in tests by default measuring units of injector delivery.
  • Page 30  ml/200str – milliliters per 200 cycles.  l/hour – liters per hour. ⑦ Return – return to previous window. ⑧ Quit – quit to operation system. Electronic measurement system STARDEX 010x Delivery and recovery target values (only for link with STAEDEX 030x) Test mode...
  • Page 31 To start working with the device just run the pump or injectors test and open measurement from the menu on the right side of the screen. Using STARDEX 0104 you can measure delivery and recovery of injectors and pump in various modes as follow: ...
  • Page 32 Supply kit. Basic Device STARDEX 0304 1 piece Power cable 1 piece Main cable for connecting six injectors 1 piece Adapter for main cable to test six Bosch injectors 1 piece Adapter for main cable to test six Delphi injectors...
  • Page 33 Additional (supplied separately) Adapter for main cable to test six injectors multisystem 1 Adapter for main cable to test six injectors multisystem 2 Fuel rail for testing six injectors assembly Fuel rail for testing one injector Pressure sensor Bosch RPM sensor...

  • Page 34: Warranty And Technical Support

    Warranty and technical support. The equipment has 1 year warranty. The manufacturer is not responsible for the damage due to violation of the operation terms, misuse, including unskillful or mistaken personnel actions and if there are traces of mechanical impact. Post-warranty service of device is performed at cost components and the work.

  • Page 35: Shipping Details

    Shipping details. The device is packed into a bubble wrap and a carton box. Weight 18 kg. Length 600 mm. Width 400 mm. Height 400 mm. MANUFACTURED BY: OY STARDEX LTD PULTTITIE 2 00880 HELSINKI FINLAND +358 (0)44 5523130 info@stardex.fi www.stardex.fi...