Stardex 0304 User manual

HELSINKI, FINLAND, 2015
COMMON RAIL INJECTORS TESTER
STARDEX® 0304

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.
Getting the electrical charges on device body is strongly prohibited!
Ingress of moisture inside the device is strictly unacceptable!
Device body is constructed to protect its components from mechanical impact while
operating. Avoid body damage, do not drop the device and do not put any heavy objects on
its cover.
At any sign of device defect, as smoke, sparking or specific smell, unplug the device
immediately and contact the nearest STARDEX service center.
All cables, connected to the device, must be supplied with standard plugs without
mechanical damage.
There are no self-repairable parts inside the device. It is strongly prohibited to open the
device.
Store and use away from children and pets.
The device is designed to work with common rail system. A user must understand the
structure and principle of operation of injection systems.
Incorrect use of the device can lead to breakage of the equipment or user’s injury.

Specifications and operation directions
Dimensions
450х400х200 mm
AC power supply
220V 50Hz or 110V 60Hz
Power consumption in stand-by mode
40W
Power consumption in load mode
400W
Operating temperature
From -100С to + 500С
Relative air humidity
not more than 90% at 250С

Purpose and range of application.
STARDEX 0304 is a highly professional universal device for testing pumps and
injectors of Common Rail system.
The device is designed to work with Common Rail systems by Bosch, Delphi, Denso,
Siemens, Caterpillar, Cummins and is also able to test all mechanical injectors as well
as nozzles of the unit-injectors.
The device is specified to test from one (combined with a hand pump) to six (while
using a test bench) injectors simultaneously.
It works both with electromagnetic and piezoelectric Common Rail injectors.
It enables to test current characteristics of an injector, displaying a high-precision
current graph on the screen.
The device is equipped with a full-fledged industrial PC system powered by Ubuntu
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.
The memory of the device contains approximately 1500 test-plans for checking
pumps and Common Rail injectors: Bosch, Delphi, Denso, Siemens, Caterpillar,
Cummins and over 10000 test-plans for checking mechanical injectors of different
manufactures.
The device STARDEX 0304 combined with the bench is a full-fledged, highly
professional solution, which enables doing completed test and setting of Common
Rail system pumps and injectors according to all necessary parameters in semi-
automatic mode, following step-by-step instructions contained in the device in the
form of test-plans.
The device is suitable for fitting out any high pressure pump test bench, including
test benches without measuring unit.

Connectors and control buttons.
①Power cable connector.
②Power switch.
③RPM sensor connector.
④Pressure sensor connector.
⑤Injector cable connector.
⑥Regulator connector 1.
⑦Regulator connector 2.
⑧Regulator connector 3.
⑨USB ports.
⑩Output for external display.
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①Front panel light diode
Has 3 states:
No light –the device is de-energized.
Red light –standby mode.
Green light –the device is on.
②On/off button.
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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.
Connect the pressure sensor to the pressure sensor connector using the appropriate cable.
Connect the fuel rail pressure regulator to regulator connectors 2, 3 using the appropriate
cables.
Connect injectors to the injector cable connector using the appropriate cable.
Switch on the power button.
Run the operating system using the on/off button on the front panel.
Once the operating system is loaded, the device is ready to be used.
To switch off the device, press the on/off button on the front panel of the device. When
the light diode is red, switch off the power button.

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.
①HAND PUMP is a mode for testing mechanical and common rail injectors with the hand
pump.
②TEST BENCH is a mode for testing injectors and common rail pumps on the high
pressure pump bench.
③DEFAULT if the field is ticked the next chosen mode will be loaded by default during the
following launch.
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HAND PUMP (MAIN > HAND PUMP)
After going to HAND PUMP, the hand pump mode menu will be displayed.
①COMMON RAIL –testing of Common Rail injectors on the hand pump (express test).
②MECHANICAL –testing of usual mechanical injectors on the hand pump.
③DEFAULT –if the field is ticked, the next chosen mode will be loaded by default, during
the following launch.
④Quit to main menu (MAIN).
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High pressure pump bench (MAIN > TEST BENCH)
After going to TEST BENCH, the high pressure pump bench menu will be shown on the
display.
①INJECTORS –testing of common rail injectors on the high pressure pump bench in hand
or semi-automatic mode.
②PUMPS –testing of common rail pumps on the high pressure pump bench in hand or
semi-automatic mode.
③DEFAULT - if the field is ticked, the next chosen mode will be loaded by default, during
the following launch.
④Quit to main menu (MAIN).
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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.
①BOSCH –electromagnetic injectors Bosch.
②DELPHI –electromagnetic injectors Delphi.
③DENSO –electromagnetic injectors Denso.
④SIEMENS –piezoelectric injectors Siemens.
⑤PIEZO BOSCH –piezoelectric injectors Bosch.
⑥CATERPILLAR –electromagnetic injectors Caterpillar.
⑦Quit to main menu (MAIN).
All Common Rail injectors have different current-voltage characteristics, so, it is
extremely important to select the type of the tested injector correctly. Incorrect choice
may cause injector’s or device’s damage!

After selecting the type of the injector, the express test window will open.
①Type of tested injector.
②Pre-installed pulse mode –beforehand installed pulse characteristics for an injector
(width, frequency).
Minimal –500 microseconds 20Hz.
Low –800 microseconds 20 Hz.
Medium –1200 microseconds 15 Hz.
High –1500 microseconds 10 Hz.
③Pulse width is the exact period of time when the injector is operating, which is called
pulse width of injection or duration of injection, and is measured in microseconds.
④Pulse frequency –the number of complete injections per 1 sec measured in Hz.
⑤START/STOP button switches on and off pulse to the injector with the determined
width and frequency.
⑥Leakage is a digital speed indication of pressure, falling in the injector, which is
expressed by the time needed for pressure to fall from 350 bar to 200 bar in the tested
injector on the hand pump.
⑦Leakage scale is a graphical display of leakage on the screen. The fixed white stripe
stands for 0. Movable stripe, that changes its color, identifies the current value of leakage.
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⑧Pressure scale is a graphical display of pressure on the screen. The movable white stripe
shows the value of pressure in the rail at the moment. The movable red stripe shows
maximal fixed pressure in the fuel rail.
⑨ Current pressure is real pressure in the fuel rail, fixed by the pressure sensor.
⑩Maximal pressure is maximal pressure fixed in the fuel rail. The value of maximal
pressure is instantly updated, when user presses on it.
⑪Quit to main menu (MAIN).
Install Common Rail injector on the hand pump and make sure all connections are sealed.
Connect injector to injector cable connector using universal cable with an appropriate cap.
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.
Press START/STOP button to start injector’s work. Create pressure in the fuel line using the
hand pump handle. Measure pressure at the beginning of an injection. Press START/STOP
button to stop injector’s work and create pressure in the fuel rail, higher than 370 bar,
using the hand pump handle. With the falling of pressure in the fuel rail, starting with 350
bar, counting of injector leakage will automatically start and will stop when it is 200 bar.
Pressure at the beginning of injection and leakage of the injector are the most important
parameters in the express diagnostics of Common Rail injectors.
Reference data on leakage of Common Rail injectors.
Bosch and Denso Common Rail injectors have the following gradation of leakage:
From -5 to -2 critically bad
From -2 to -1 relatively bad
From -1 to 0 relatively operational
From 0 to 1 good
From 1 and higher very good

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
From 3 and higher very good
Reference data at the beginning of injection on MEDIUM pulse.
Bosch cars 190 bar ± 25 bar
Bosch trucks 200 bar ± 30 bar
Denso cars, trucks 190 bar ± 40 bar
Delphi cars 175bar ± 30 bar
Delphi trucks 200 bar ± 30 bar
Siemens and Piezo Bosch 170bar ± 25 bar
These reference materials are generalized and accurate for most of Common Rail
injectors!
When conduct express diagnostics, it is important to note, that all tested Common Rail
system injectors taken from one engine have the same pressure at the beginning of the
injection, otherwise adjustment on the high pressure pump bench is required.

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.
② Quit to menu HAND PUMP.
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After selecting the type of tested injectors, the test window will open.
①Opening injector pressure –fixed pressure of the injector opening.
②Reset button cleans a value of opening injector pressure before next testing.
③Reference data is a list of the reference data about opened injector or nozzle (data span
of opening pressure in bar).
④Pressure scale is a graphical display of pressure on the screen. The movable white stripe
shows the value of pressure in the rail at the moment. The movable red stripe shows
maximal fixed pressure in the fuel rail.
⑤Current pressure is real pressure in the fuel rail fixed by the pressure sensor.
⑥Maximal pressure is maximal pressure fixed in the fuel line. The value of maximal
pressure is instantly updated when press on it.
⑦Quit to menu HAND PUMP.
Install a mechanical injector on the hand pump and make sure all connections are sealed.
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. Create pressure in the fuel rail which is enough for the injector to be activated
by the hand pump. Pressure of the tested injector is shown by big numerals in the left top
corner of the screen and by the red stripe on the pressure scale.
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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.
①Manual is a manual mode for testing on the high pressure pump bench.
②Testplan is a semi-automatic mode for testing injectors according to testplan.
③ Quit to menu TEST BENCH

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After going to TESTPLAN, the window for selecting the type of common rail injectors will
open.
①BOSCH –electromagnetic injectors Bosch.
②DELPHI –electromagnetic injectors Delphi.
③DENSO –electromagnetic injectors Denso.
④SIEMENS –piezoelectric injectors Siemens.
⑤PIEZO BOSCH –piezoelectric injectors Bosch.
⑥CATERPILLAR –electromagnetic injectors Caterpillar.
⑦Quit to menu TEST BENCH.
All Common Rail injectors have different current-voltage characteristics so it is extremely
important to select the type of the tested injector correctly. Incorrect choice may cause
injector’s or device’s damage!

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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.
② Quit to menu TEST BENCH.

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After selecting injector serial number, the window for testing Common Rail injectors on the
high pressure pump bench will open.
①Information line is a line where manufacturer and serial number of tested injectors are
shown.
②Test step shows the name of the current testing mode, the horizontal arrows change
modes.
③Target pressure is pressure which will be set in the fuel rail if you activate control of the
reducing valve by ON/OFF switch in the section PRESSURE or by the button START/STOP.
If the Common Rail bench pump has lower productivity than required for testing this type
of injectors or back flow of injector is too high, real pressure in the rail can be fixed
considerably lower than target. In such case Common Rail bench pump should be
replaced by more productive one or number of injectors tested simultaneously should be
lessened.
④Pulse width –the exact period of time when the injector is operating, which is called
pulse width of injection or duration of injection, it is measured in microseconds.
⑤Pulse frequency –the number of complete injections per 1 sec measured in Hz.