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 semiautomatic 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.
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.
1 2 3 4 9 5 8 7 6
10
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.
1
2
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.
① HAND PUMP is a mode for testing mechanical and common rail injectors with the hand
pump.
② TEST BENCH is a mode for testing injectors and common rail pumps on the high
pressure pump bench.
③ DEFAULT if the field is ticked the next chosen mode will be loaded by default during the
following launch.
1 2 3
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 DEFAULT – if the field is ticked, the next chosen mode will be loaded by default, during
the following launch.
④ Quit to main menu (MAIN).
1 2 3
4
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.
② PUMPS – testing of common rail pumps on the high pressure pump bench in hand or
semi-automatic mode.
③ DEFAULT - if the field is ticked, the next chosen mode will be loaded by default, during
the following launch.
④ Quit to main menu (MAIN).
1 2 3
4
1 2 3 4 5 6 7
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 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 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!
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