STARDEX LTD OY

HELSINKI, FINLAND

APRIL 2011

COMMON RAIL INJECTOR TESTER STARDEX™ 0302

1. Security information

Read the instructions carefully before using Stardex 0302 (the device).

The device must be connected only to AC outlet with voltage determined in the device

passport. To connect the device, use the cable from the delivery kit.

Getting of electrical charges on the equipment is strictly prohibited!

Getting liquids inside the device is strictly prohibited!

Device body is constructed to protect its components from mechanical impact while

operating. Avoid body and front panel damage, do not drop the device and do not put

heavy objects on the top of it.

In case of defect (smoke, sparks, specific smell) immediately unplug it and send to the

service center.

All cables from the delivery kit must be supplied with standard plugs and do not have

mechanical damage.

The device does not contain self repairable parts inside. It is strictly prohibited to open the

device.

Keep and use the device in the areas inaccessible to children and pets.

The device is designed to work with Common Rail system. The user must understand

structure and working principle of injection systems.

Incorrect use of the device may cause the damage of the device or user’s injury.

2. Technical requirements and operation directions

European version of the device

Dimensions 427.5х351х141.5 mm

AC power supply 220V 50Hz

Power consumption in stand by mode 60 W

Power consumption in full load mode 300 W

Operating temperature from -100С to + 500С

Relative humidity no more than 90% at 250С

American version of the device

Dimensions 427.5х351х141.5 mm

AC power supply 110V 60 Hz

Power consumption in stand by mode 60 W

Power consumption in full load mode 300 W

Operating temperature from -100С to + 500С

Relative humidity no more than 90% at 250С

Supply voltage and the version of the device are determined in the device passport!

3. General Description

STARDEX 0302 is a highly professional universal device for testing all diesel injectors

of all models and manufacturers.

The device is specialized to test Common Rail injectors manufactured by Bosch,

Delphi, Denso, Siemens, Caterpillar and it can test all of the mechanical injectors, as

well as nozzles of the unit-injectors.

The device can test from one (complete with hand pump) up to six (when used on the

test bench) injectors.

It works both with electromagnetic and piezo Common Rail injectors.

It is possible to check the electromagnetic coil and see the precise current plot on the

screen.

The device is controlled by keyboard and mouse or by control buttons on the front

panel of the device. All necessary information is displayed on 6.5” color LCD screen.

There is a possibility to connect the device the external monitor.

Stardex 0302 combined with a hand pump allows you to diagnose Common Rail

injectors according to the following parameters: efficiency, leakage, the quality of

injection, the pressure in the beginning of injection and the state of electromagnetic

coil (solenoid) or injector piezo element .

The memory data contains more than 650 test-plans for Common Rail Bosch, Delphi,

Denso, Siemens injectors and pumps and there are more than 10.000 test plans to

check mechanical injectors of different manufacturers.

The device Stardex 0302 connected to Stardex 0201 USB with interface cable is a

complete, highly professional kit with the possibility of a full testing and setting of

any Common Rail Bosch, Delphi, Denso, Siemens pumps and injectors according to all

required parameters in semi-automatic mode, following step by step instructions

contained in the test plans of the device.

This kit is suitable for upgrading any test bench including test benches without

measuring unit.

4. Switching on\off the device, connectors, control buttons.

1. Plug the device to AC outlet according to technical characteristics of the device with

the power cable from the delivery kit.

Pressure sensor

connector

Display input for

front panel monitor

USB

ports

Video

output

Power cable

connector

Power switch

Injector cable

connector

Mode

Plot Menu

Select

Start

Stop

Navigation

Power

button Navigation

n

2. Connect the display input for front panel monitor to video output or connect the

video output to the external monitor.

3. Connect the keyboard and mouse to the USB ports on the back panel.

4. Connect the required cords to the pressure sensor and injectors in the appropriate

ports on the back panel.

5. Press the power button on the back panel.

6. Start operating system by clicking power button on the front panel. After

downloading the operating system the device is ready for use.

7. To turn off the device press power button on the front panel. When the LED on the

front panel turns red, turn off the power unit with power switch on the back panel.

5. Interface description

CR injector testing on hand pump

Start/Stop button

Status indicator

Leakage

Leakage

Scale

Maximal

pressure

Nominal

pressure

Reset

button

CR injector

testing on hand

pump

Mechanical

injector testing

on hand pump

CR

injector

testing on

test bench

Tested injector type

Pulse frequency

Pulse mode preset

Pulse width

Menu

Current

plot

CR pump

testing on

test bench

Tested injector type - the mode determined by CR injector type:

Bosch – electromagnetic injectors Bosch.

Delphi – electromagnetic injectors Delphi.

Denso – electromagnetic injectors Denso.

Siemens – piezoelectric injectors Siemens.

Piezo Bosch – piezoelectric injectors Bosch.

Caterpillar – electromagnetic injectors Caterpillar.

All Common Rail injectors have different volt-ampere characteristics, that is why it is

extremely important to select correctly the type of the tested injectors. The wrong choice

can cause damage to the injectors and to the device!

Pulse mode preset – predetermined characteristics of the pulse (width, frequency) on the

injector.

Minimal - 500 microseconds 20 Hz.

Low – 800 microseconds 20 Hz.

Medium - 1200 microseconds 15 Hz.

High - 1500 microseconds 10 Hz.

Pulse 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.

Pulse frequency – the number of full injections per 1 sec, measured in Hz.

Start\Stop button – turns on & off the pulse to the injector with determined width and

frequency.

Status indicator has 2 states:

Not active - there is no pulse to the injector.

Flashes green – there is pulse to the injector.

Leakage – speed of pressure falling in digital rate, expressed through the time it takes to

reduce pressure from 350 bar to 200 bar in the tested injector on a hand pump.

To get exact results there mustn’t be leakage in different connecting points of hand pump

and fuel line!

Leakage scale – graphical display of leakage on the screen.

Nominal pressure – real pressure in the fuel rail that is fixed by a pressure sensor.

Maximal pressure – maximal pressure fixed in the fuel rail, over the time specified in the

menu.

Reset button – instantly updates the maximum pressure value.

Mechanical injector testing on hand pump

Nozzle or injector type – select injector or nozzle type from the list.

Reference value – reference values note for the selected injector or nozzle type (opening

pressure min/max bar).

Injector opening pressure – opening pressure of the tested injector.

Reset button – press this button to reset injector opening pressure.

To obtain the precise value of opening pressure of the mechanical injector make the hand

pump pushes several times.

Injector or nozzle type

Injector opening

pressure

Reset

button

Reference values

Tested injector type

Pulse width

Pulse frequency

Start/Stop button

(injector)

Real

pressure

Set cycles

count

Test mode indicator

button

Target

pressure

Information

line

Result button

Previous/next

buttons

S/N select button

Information window

Report button

Injectors

select

buttons

Status

indicator

Start/stop

button

(pressure)

CR injector testing on test bench

Test mode indicator button changes test mode.

Injector – CR injector testing according to test-plan.

Manual – CR injector testing without test plan with user’s parameter settings.

The inscription on the indicator button corresponds to the selected test mode.

S/N select button - opens manufacturer and serial number select window of the tested

pump or injectors depending on selected test mode.

Information line – displays the manufacturer and serial number of tested pump or

injectors.

Information window – describes the user’s step by step actions for pump or injector test

(test-plan).

Result button – enters the values of measured parameters in the report.

Previous/next buttons – is used to move between different test steps in information

window.

Report button – displays a full report on the results of pump or injectors testing.

Real pressure – pressure sensor readout.

Start\ Stop Button (injector) – turns on and off pulse to the activated injectors with the

determined width and frequency.

Start\ Stop Button (pressure) – turns on and off pressure control in fuel rail. When start is

pressed, PCV (pressure control valve) installed at fuel rail, is controlled in such a way that

real pressure in rail is set at the level of target pressure. When stop is pressed , there is no

signal to PCV . This function is performed only for Stardex 0302 when Stardex 0201 USB is

connected to it with interface cable.

Injectors select buttons – give the possibility to activate/deactivate selected injectors.

Figures on the buttons correspond to the numbered cables.

Status indicators have 3 states:

1. Glow green - injector is activated.

2. Blink green - the pulse is given to the injector.

3. Do not glow - injector is deactivated.

Set cycles count – is the button that opens menu of injection time control. This function is

used when CR injectors are tested on the test bench without measuring unit for cyclic flow

measuring.

Test bench rotation – is the field where user enters the rotation of test bench (data from

test bench tachometer).

Cycles number

Test bench rotation

Timer activation

Cycles number – is the field where user enters the number of cycles for cyclic flow

measuring (default 200).

Timer activation – if timer is enabled, then the signal to the injectors after pressing Start

button (injector) will be limited in time. This period of time is calculated automatically and

is based on the test bench rotation and the cycles number.

CR pump testing on test bench

First channel control

Second channel control

Third channel control

Real pressure

General Stop

Test mode indicator button

Start/Stop

Current

Duty cycle

Pressure control

Duty cycle

control

Current

control

Target pressure

Real pressure – pressure sensor readout.

Target pressure – the pressure that will be in fuel rail after pressing Start button (only for

1st Channel in pressure control mode).

Test-mode indication button – changes the test mode:

Pump – CR pump test using test-plan.

Manual – CR pump test without test-plan and with user’s parameter settings.

Duty cycle – value of duty cycle on the channel.

Current - value of current on the channel.

Pressure control - turns on the pressure control mode (only for the 1st channel).

Duty cycle control - turns on the duty cycle control mode on the channel.

Current control – turns on the current control mode on the channel.

Start/Stop button – turns on and off the signal on the channel. User sets characteristics of

signal by control mode and the value of the target pressure, current or duty cycle.

General Stop – turns off signal to all channels.

CR pump testing on the test bench is performed only for Stardex 0302 when Stardex 0201

USB is connected to it with interface cable from the delivery kit from Stardex 0201 USB.

Stardex 0302 channel numeration corresponds to Stardex 0201 USB channel numeration.

Modes and methods of signal control on Stardex 0302 corresponds to modes and

methods of signal control on Stardex 0201 USB.

Current plot

Current scale – the current in the injector circuit, measured in amperes.

Time scale – time measured in microseconds.

Check box – it is set to the left from the injector number, the plot of which is shown on the

screen.

Refresh button – instantly updates the current plot.

Change Mode – increases the scale of the graph in the beginning of pulse. Second time

button press returns to default view.

Check box

Refresh

button

Time

scale

Current

scale

Change

Mode

Menu

Pressure sensor type – the user sets parameter according to the type of pressure sensor to

which the device is connected.

Max pressure reset time – this parameter corresponds to the time interval, in seconds,

after which, maximum pressure is updated in hand pump mode.

Plot auto refresh time – this parameter corresponds to the period of time when current

plot updates (in seconds)

Find CRSD – after pressing this button the attempt of connection with Stardex 0201 USB is

performed. Stardex 0201 USB must be connected to Stardex 0302 with interface cable from

the Stardex 0201 USB delivery kit.

Connection Status – has 2 conditions:

CRSD Connected – Stardex 0201 USB connected.

CRSD Disconnected – Stardex 0201 USB not found.

Quit to system – quit to operating system.

Pressure sensor type

Max pressure reset

time

Plot auto refresh

time

Quit to system

Find CRSD

Connection Status

6.Testing of Common Rail injectors on hand pump (express

diagnostics)

Switch on Stardex 0302. Install Common Rail injector on hand pump and ensure that all

connections are sealed. Connect injector to Stardex 0302 using universal cable with a

suitable cap. Connect Stardex 0302 to pressure sensor of one injector fuel rail which is set

on hand pump. Select Express mode. Select the type of the tested injectors. Select the

width and the frequency of the pulse. Press Start \ Stop to start the injector. Moving the

handgrip at hand pump, create the pressure in the fuel line. Measure the pressure in the

beginning of injection. Press the button Start\Stop to stop the injector and moving the

handgrip to create the pressure in the fuel line more than 370 bar. With the fall of pressure

in fuel line, starting with 350 bar, the counting of the injector leakage will begin and when

the pressure will be 200 bar the counting will stop. Pressure in the beginning of injection

and leakage of the injector are the most important parameters in express diagnosis of

Common Rail injectors.

Reference data on the leakage

Common Rail Bosch and Denso injectors have the following graduation on the leakage:

From -5 to -2 Very bad condition

From -2 to -1 Bad condition

From -1 to 0 Fair condition

From 0 to 1 Good condition

From 1 and above Excellent condition

Common Rail Delphi, Piezo Bosch, Siemens injectors have the following graduation on the

leakage:

From -5 to -1 Very bad condition

From -1 to 0 Bad condition

From 0 to 1 Fair condition

From 1 to 3 Good condition

From 3 and above Excellent condition

Reference data in the beginning of injection on Medium pulse

Bosch car 190 bar ± 25 bar

Bosch trucks 200 bar ± 30 bar

Denso cars and trucks 190 bar ± 40 bar

Delphi car 175 bar ± 30 bar

Delphi trucks 200 bar ± 30 bar

Siemens и Piezo Bosch 170 bar ± 25 bar

These reference materials are generalized and authentic for most Common Rail injectors!

It is important to know that all Common Rail injectors taken from one engine, have the

same pressure in the beginning of injection in different pulse modes, otherwise necessary

settings of the injectors must be done on the test bench.

7.Diagnostics of mechanical injectors on hand pump

Install mechanical injector on hand pump and ensure that all connections are sealed.

Connect Stardex 0302 to pressure sensor of one injector fuel rail which is set on hand pump

with appropriate cable from the delivery kit. Select Mech mode in Stardex 0302. With the

help of hand pump create the pressure in the fuel line enough to open the injector nozzle.

The opening pressure of the tested injectors is displayed with large numbers in the low left

corner of the screen.

To get the exact value of the injector opening pressure, move the handgrip of hand pump

a few times!

8.Diagnostics of Common Rail injectors on the test bench

Install Common Rail pump on the test bench. Connect test oil supply from the test bench to

the pump inlet. Install six injectors fuel rail on the test bench and connect it with pump high

pressure outlet using high pressure tube. Return flow of pump and fuel rail connect to tank

inlet of the test bench. Connect Common Rail injectors to fuel rail with high pressure tubes.

Delivery and return flow of injectors connect to measuring unit (ex. Measuring unit of the

test bench). Connect pressure sensor of fuel rail to Stardex 0201 USB. Connect pressure

regulator of fuel rail to the fist channel of Stardex 0201 USB. Connect Stardex 0302 to

injectors with the appropriate cable from the delivery kit. Connect Stardex 0201 USB and

Stardex 0302 with interface cable from the delivery kit. Turn on Stardex 0201 USB and

Stardex 0302. Set the connection to Stardex 0201 USB in the menu of Stardex 0302. Select

Bench tab in Stardex 0302 and set Injector mode. Select manufacturer and serial number of

the tested injectors. In Stardex 0302 activate the connected injectors by injector select

buttons according to the numbered cables. Follow the step by step instructions in

information window of Stardex 0302.

Conceptual connection pattern

While working at the high pressure test bench, use the protective clothes, to avoid injury

in case of emergency situations!

9.Diagnostics of Common Rail pumps on the test bench

Install Common Rail pump on the test bench. Connect test oil supply from the test bench to

the pump inlet. Install six injector fuel rail on the test bench and connect it with pump high

pressure outlet using high pressure tube. Close the rest fuel rail outlets by special plugs.

Connect return flow of pump and fuel rail to measuring unit (ex. Measuring unit of the test

bench or Stardex 0101). Connect pressure sensor of fuel rail to Stardex 0201 USB. Connect

pressure regulator of fuel rail to the fist channel of Stardex 0201 USB. Connect pump

pressure regulators (if exists) to the second and third channels of Stardex 0201 USB.

Connect Stardex 0201 USB and Stardex 0302 with interface cable from the delivery kit. Turn

on Stardex 0201 USB and Stardex 0302. Select Bench tab in Stardex 0302 and set Pump

mode. Select manufacturer and serial number of the tested pump in Stardex 0302. Follow

the step by step instructions in information window of Stardex 0302.

Conceptual connection pattern

Note: While testing some Bosch CP1 pumps where pressure regulator is similar to pressure

regulator in six injectors fuel rail, install pump regulator in the fuel rail and install at its

place a special plug from the delivery kit of six injector fuel rail.

10. Delivery kit

Basic

Stardex 0302 1 piece

Power cable 1 piece

Universal cable 1 piece

Universal cable cap for Bosch injector 1 piece

Universal cable cap for Delphi injector 1 piece

Universal cable cap for Denso injector 1 piece

Universal cable cap for Siemens/Bosch injector 1 piece

Multisystem universal cable cap # 1 1 piece

Multisystem universal cable cap # 2 1 piece

Cable to connect 6 Bosch injectors 1 piece

Cable for connection to Bosch pressure sensor 1 piece

VGA cable 1 piece

Computer mouse 1 piece

Computer Keyboard 1 piece

Technical Description 1 piece

Optional

Cable to connect 6 Delphi injectors Opts.

Cable to connect 6 Denso injectors Opts.

Cable to connect 6 Siemens/Bosch injectors Opts.

Multisystem cable # 1 to connect six injectors Opts.

Multisystem cable # 2 to connect six injectors Opts.

1 injector fuel rail Opts.

6 injectors fuel rail Opts.

Bosch pressure sensor Opts.

11. Warranty and technical support

The equipment has 2 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.

12. Package

The product is packed into bubble wrap and carton box.

Manufactured by:

OY STARDEX LTD PULTTITIE 2 00880 HELSINKI FINLAND +358 44 5523130 +358 45 2770460 +358 9 7531278 www.stardex.fi