Helsinki 2013/2014

UIS and PLD TESTER

STARDEX® 1002

Safety rules for working with STARDEX 1002 device.

Before using the device STARDEX 1002 (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 of electrical charges on the body of the device is strongly prohibited!

Getting of liquid inside the device is strongly prohibited!

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

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

heavy objects on its cover.

At any sign of defects such 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 of 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 UIS and PLD systems. A user working with the device

must understand the structure and principle of operation of injection systems.

Incorrect use of the device may lead to breakage of the equipment or user’s injury.

Specifications and operation directions.

STARDEX 1002

Dimensions 450x415x95 mm

AC power supply 100V-240V 47Hz-63Hz

Power consumption in stand-by mode 40W

Power consumption in load mode 500W

Operating temperature from -100С to + 500С

Relative air humidity not more than 90% at 250С

CamBox

Dimensions 430x240x225 mm

Purpose and range of application.

STARDEX 1002 is a highly professional universal device for testing unit injectors (UIS)

and individual pumps (PLD) on the high pressure pump bench, the device is supplied

together with CamBox and is intended to work with Bosch, Delphi (Lucas), Cummins,

Siemens, Caterpillar, Detroit systems.

The device is equipped with its own measuring unit; it speeds up and facilitates

operator’s work, and makes it suitable for fitting out any high pressure test bench,

including the bench without its own measuring unit.

It works both with electromagnetic and piezoelectric valves of UIS and PLD.

It enables to test current characteristics of an injector displaying the precise diagram

on the screen, and enabling to define the state of an electromagnetic coil (solenoid)

or piezoelement of an injector.

The device is supplied with 8,4" touch-screen, and is controlled by a keyboard and a

mouse or by navigating buttons on the front panel. There is possibility to connect the

device to an external monitor.

The device STARDEX 1002 + CamBox combined with the test bench is a full-fledged

highly professional solution which enables completed test and setting of pump-

injectors and individual pumps according to all necessary parameters in semi-

automatic mode while following step-by-step instructions contained in the device

in the form of test-plans.

Connectors and control buttons STARDEX 1002.

①RPM sensor connector.

②Injection delay sensor connector.

③Power cable connector.

④USB ports.

⑤Injector universal cable connector.

⑥Power switch.

⑦Output for external display.

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7

2 3 4

6 5

①Navigation panel – arrows to switch measured parameters, a square to select.

②MODE – switches modes.

③FLOW – resets flowmeter.

④MENU – opens the menu of the device.

⑤On/off button.

⑥Front panel light diode:

No light – the device is off power.

Red light – the standby mode.

Green light – the device is on.

⑦START/STOP – on/off impulse to the injector (stands for the same button on the screen).

⑧Fuel flowmeter line input.

⑨Fuel flowmeter line output.

1 4 3 2 5 6

7 8 9

Installing CamBox to the test bench.

Place CamBox to the test bench stand and fix it using fasteners from the supply kit ④ and

⑥.

Then fix CamBox coupling ① in the bench shaft ③.

Then pour motor oil 10w40 into the scupper filler② controlling the level according to the

indicator⑤.

Connect RPM sensor ⑦ using the cable from the supply kit into the relevant connector of

STARDEX 1001.

3 4 6

1 2

5 7

Setting of pump injector into CamBox.

Place the tested injector into the proper adaptor ④ and fix it using a cramp with a screw

③.

3 4

1 4 2 6 5

5

7 8

Fix the pusher ① according to the type of the injector.

Place the adapter with the injector in it to CamBox as shown on the picture and fasten it by

screws from the supply kit ⑤.

Fix the injection delay sensor ⑦ to the injectors nozzle with the proper adaptor ⑥

connected to it.

Connect delivery of the bench supply pump to the input of the adaptor fuel chamber ④,

and the backflow from the adaptor to drain into the bench tank.

Connect the output ⑧ from injection delay sensor to the input of STARDEX 1001

flowmeter, and output of the flowmeter to the bench tank.

Connect injector to STARDEX 1001 using the cable with the proper cap ②.

Switch on the power on the back panel of STARDEX 1001 and run a loading of the device by

the button on the front panel (switch off by the same button).

Injector cable description.

① The long tale is used for most connections (2 wired injectors).

② The short tale is used to connect second solenoid valve (Delphi E3).

2 1

1

1 2

STARDEX 1002. Start operating.

After the loading of the device the window of selection of the tested pump injector

manufacturer is displayed.

After selecting the injector manufacturer the window for selecting a serial number will

open.

After selecting the serial number the window for selecting the quantity of the injectors

tested will open.

Screen for pump injectors testing.

After selecting the manufacturer, the serial number, and the quantity of the injectors

tested the window for injectors testing will open.

1. Switch on the test bench and set the necessary pressure of the supply pump,

commonly 3-4 bar.

2. Fix the bench drive revolutions ⑯ on the level of target revolutions ⑮.

3. Push START ⑪ for delivery of the leading impulse to the injector with the given

length ⑬ and advance angle ⑭.

4. Within some seconds the delivery of the pump injector will be displayed in the

measuring tube ③ in graphical and digital form (in the selected measuring units

④), and two horizontal lines mean a possible limit of declinations which are digitally

reflected as well ⑤.

5. Put down the received delivery result in to the report using STORE button ② or

manually pressing the result window ①. While putting down the delivery result into

the report, the results of injection delay ⑫ will be put down into the report

automatically together with BIP signal ⑩, which are displayed on the diagram ⑨ in

graphical and digital form.

8 7

6

1

4

3

2

1

16

15

9 10 12 11 13 14

5

6. Proceed to the next test using navigation arrows ⑥ and repeat the steps from the

second to the fifth. Standard injector test includes 5 tests: Air cleaning, High load,

Medium load, Low load, Start test.

7. After finishing all the tests stop revolutions of the bench drive, switch off the supply

pump and install the next injector into CamBox.

8. With the help of injector selection buttons ⑧ proceed to testing of the next injector

and repeat steps from the first to the eighth.

9. After finishing the injector set test go to the result overview (additional menu on the

right of the screen) and print the report.

10. In order to proceed to test of the other injector type, go to the menu of injector

selection by pressing the inscription ⑦.

The test-plan for every test has bench revolutions ⑮, injection impulse length ⑬, signal

advance angle ⑭, measuring units of the measuring block ④ already specified, but a user

is able to change all parameters of the test at his discretion. There is also a possibility to

change Volt-Ampere characteristics of the signal, the procedure is described further.

Additional menus.

There are additional menus in the right part of the screen. Additional menus can vary

depending on other connected STARDEX devices or test mode.

Current graph.

①Current scale – intensity of current in the injector circuit measured in Ampere.

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2

4

3

②Time scale – time measured in microseconds.

③Navigation between different graphs (current graph, injection delay sensor graph,

revolutions uniformity of CamBox axle graph).

④Return to the previous screen.

Injection delay sensor graph.

①Current scale – intensity of current in the injector circuit measured in Ampere.

②Time scale – time measured in microseconds.

③Navigation between different graphs (current graph, injection delay sensor graph,

revolutions uniformity of CamBox axle graph).

④Setting of injection delay sensor sensitivity.

⑤Return to the previous screen.

1

5

3

2

4

Rotation uniformity graph.

①CamBox average revolutions.

②Navigation between different graphs (current graph, injection delay sensor graph,

revolutions uniformity of CamBox axle graph).

③Return to the previous screen.

Rotation uniformity graph reflects acceleration and deceleration of CamBox axle rotation

depending on loads from injectors. The red circle is the ideal speed per one axle rotation;

the white curve shows real rotation speed of the CamBox axle. In the case the white curve

varies inside or outside from the red circle (outside – acceleration, inside - deceleration) for

more then 1/3 of the circle radius, the mass of bench flywheel must be increased.

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2 1

1

6

2 5 3 4

Setting of Volt-Ampere characteristics of the impulse to the injector.

①Signal voltage.

②First phase current.

③Second phase current.

④First phase length.

⑤Dual-coil injector – note while testing Delphi E3.

⑥Go back to the previous window.

General settings.

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2

6

3

5

4

①Screen resolution – sets resolution of an external monitor.

②Set injector delivery units which are used by default in tests.

ml/min – milliliters per minute.

ml/200str – milliliters per 200 cycles.

③Touchscreen calibration.

④Software and hardware version.

⑤Return – return to previous window.

⑥Quit – quit to operation system.

Supply kit.

Basic

STARDEX 1002 simulator 1 piece.

CamBox 1 piece.

Coupling with fasteners for connecting CamBox to bench drive 1 piece.

Adaptor for Volvo (Bosch, Delphi A3), Iveco unit injectors 1 piece.

Adaptor for Scania unit injectors 1 piece.

Adaptor for Delphi E1, E3 unit injectors 1 piece.

Power cable 1 piece.

Rotation sensor cable 1 piece.

Piezo sensor for injection delay measuring 1 piece.

Universal cable for unit injectors 1 piece.

Universal cable adaptor Type 1 1 piece.

Universal cable adaptor Type 2 1 piece.

Universal cable adaptor Type 3 2 piece.

Nozzle adaptor 7mm 1 piece.

Nozzle adaptor 9mm 1 piece.

Fuel pipe 4 m.

Fittings for flowmeter line connection 2 pieces.

Technical description 1 piece.

Additional (supplied separately)

Cummins unit injector adapter type 1

Cummins unit injector adapter type 2

Detroit unit injector adapter

Volkswagen unit injector adapter type 1

Volkswagen unit injector adapter type 2

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. 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

info@stardex.fi

www.stardex.fi