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Stardex 0602 Manual

Common rail injectors tester
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COMMON RAIL INJECTORS TESTER
STARDEX® 0602

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Summary of Contents for Stardex 0602

  • Page 1 COMMON RAIL INJECTORS TESTER STARDEX® 0602...
  • Page 2 Safety rules for working with STARDEX 0602. Before using the device STARDEX 0602 (further “the test bench”) read this manual carefully. The test bench should be plugged only in a three-phase circuit of alternative current 380W with grounding. In order to power up the test bench use only a supply cable from the delivery kit.
  • Page 3  STARDEX 0602 is a highly professional universal test bench for testing injectors of Common Rail system of different manufacturers, brands and models.  STARDEX 0602 is reliable and easy to work with. The process of injector testing is completely automatic and does not require any specific knowledge and skills from an operator.

  • Page 4: Installing And Connecting

     STARDEX 0602 enables to conduct a test of current characteristics of an injector, with the precise diagram which is displayed on the screen.  STARDEX 0602 also enables to get a repair code for Delphi injectors.  The test bench is controlled by a keyboard and a mouse or by navigating buttons on the front panel.
  • Page 5  Pour a calibration fluid into the mouth of the tank and open its ventilation by turning a special valve on the cover of the tank.  Switch on the power module by its button situated on the back panel of STARDEX 0303.
  • Page 6  Connect a wireless module for the mouse and the keyboard to a free USB port.  (By option) Connect the detachable screen from the supply kit.  Fix back and front panels on the test bench again.  Plug into a three-phase circuit of alternative current 380W with grounding with the power cable.
  • Page 7  The test bench is ready to be used after the operation system is loaded.  The test bench is switched off by the OFF button on the front panel of STARDEX 0303. When the light diode on the front panel of STARDEX 0303 is red, switch the lever of the automatic power on the left panel of the test bench in OFF-position.
  • Page 8 ⑭ Front panel light diode  Does not light – STARDEX 0303 is unpowered.  Lights red – STARDEX 0303 is in stand-by mode.  Lights green – STARDEX 0303 is on. ⑮ START/STOP switches on/off control of motor, pressure and pulse of injector.
  • Page 9 ① Fuel rail plug. ② High pressure pump outlet. ③ Injector delivery measuring lines. ④ Injector back flow measuring lines. ⑤ Pressure regulator. ⑥ Back flow of fuel rail.
  • Page 10 ⑦ Pressure sensor connector. ⑧ Pressure regulator connector. ⑨ Injector connector. ⑩ Pressure sensor. Setting of injectors on the test bench. Turn plugs off the fuel rail. Fix high pressure pipes from the kit on those places. Attach injectors to high pressure pipes. Fix appropriate adapters on injector nozzles and connect them with appropriate injector delivery measuring lines.
  • Page 11 Main display (INJECTORS). ① MANUAL is a manual mode for testing injectors. ② TESTPLAN is a semi-automatic mode for testing injectors according to testplan. ③ AUTO is an automatic test mode. ④ CODING - getting an injector repair code. Testing of injectors in TESTPLAN mode. After going to TESTPLAN the screen for selecting the type of Common Rail injectors will open.
  • Page 12 ① BOSCH – electromagnetic injectors Bosch. ② DELPHI – electromagnetic injectors Delphi. ③ DENSO – electromagnetic injectors Denso. ④ SIEMENS – piezoelectric injectors Siemens. ⑤ PIEZO BOSCH – piezoelectric injectors Bosch. ⑥ CATERPILLAR – electromagnetic injectors Caterpillar. ⑦ Quit to INJECTORS screen. All Common Rail injectors have different current-voltage characteristics so it is extremely important to select the type of the tested injector correctly.
  • Page 13 After selecting injector serial number the screen for testing injectors in TESTPLAN mode will open. ① Headline 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.
  • Page 14 Quantity of fields for inserting displayed on the screen depends on quantity of tested injectors. ⑨ Information area is an opening section where the mode of the current test step is described. ⑩ Motor revolutions are real revolutions of the high pressure pump measured by RPM sensor.
  • Page 15 ⑲ Quit to Main screen. Install injectors onto the test bench. Select type and serial number of tested injectors. Select tested injectors by select buttons. Press START/STOP and wait till pump revolutions and fuel rail pressure are set on the given level. Wait about a minute so that injectors fill line of the flow meter and make it free from air.
  • Page 16 Injector testing in AUTO mode. After selecting AUTO mode, the screen for selecting injector type will open. ① BOSCH – electromagnetic injectors Bosch. ② DELPHI – electromagnetic injectors Delphi. ③ DENSO – electromagnetic injectors Denso. ④ SIEMENS – piezoelectric injectors Siemens. ⑤...
  • Page 17 After choosing the injector type the screen 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 18 ② Select buttons are used for choosing the number of injectors tested. Each numeral corresponds to numerated wire connected to injector.  Lights red – injector is selected  Winks red – injector is pulsed  Does not light – injector is not selected ③...
  • Page 19 After selecting serial number the display of CODING test will open. ① Headline is a line where type and number of tested injectors are displayed. ② Select buttons are used for choosing the number of injectors tested. Each numeral corresponds to numerated wire connected to injector. ...

  • Page 20: Additional Menu

    ① Repair codes are new codes for tested injectors received as a result of the CODING test. Additional menu. If you move the mouse pointer to the right part of the display the additional menu will appear. ① Current graph. ②...
  • Page 21 ④ Settings. ⑤ Result screen. Current graph. ① Return – go back to the previous screen. ② Current scale – intensity of current in the injector circuit measured in Ampere. ③ Time scale – time measured in microseconds. ④ Select buttons – activate/deactivate display of the current graph for selected injector. Color of graphs corresponds to color of buttons;...

  • Page 22: Flow Meter

    Flow meter. ① Result store is a button which, when pressed, saves current values of delivery and back flow of injectors into the result screen. ② Measuring tube is a graphical image of delivery and back flow on the display. Four tubes from the left part of the display show injector delivery, four tubes on the right show back flow.

  • Page 23: Result Screen

    ⑧ Pulse length. ⑨ Pulse frequency. ⑩ Injector pulse indicator shows the state of the injector pulse  winks – pulse is delivered to injectors  does not wink – pulse is off ⑪ Back flow measuring units is a switchable indicator which, when pressed, changes measuring units for back flow.
  • Page 24 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 test bench.  1500 bar  1800 bar ③ Injector delivery measuring units sets used in tests by default measuring units of injector delivery.

  • Page 25: Supply Kit

    Supply kit. Basic STARDEX 0602 1 piece Cable for connecting four Bosch injectors 1 piece Cable for connecting four Delphi injectors 1 piece Cable for connecting four Denso injectors 1 piece Cable for connecting four Siemens/Bosch 1 piece Multisystem cable for connecting four injectors 1...

  • Page 27: Warranty And Technical Support

    Post-warranty service of device is performed at cost components and the work. The manufacturer reserves the right to design modifications, equipment and the warranty period without advance notice. MANUFACTURED BY: OY STARDEX LTD PULTTITIE 2 00880 HELSINKI FINLAND +358 (0)44 5523130 www.stardex.fi...

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