COMMON RAIL INJECTOR TESTER STARDEX 0601

Transcription

1 COMMON RAIL INJECTOR TESTER STARDEX 0601

2 1. Security information Read this operating manual carefully before using Stardex 0601 ( Device or Test bench ). The device must be connected only to the three-phase alternative current power supply grounded circuit 400V. To connect the device use power cable included in the delivery kit. Applying of any electrical charges to the enclosure of device is strictly prohibited! Getting any liquids inside the device must be avoided! Device body is designed to protect its components from mechanical impact while operating. Avoid enclosure and front panel damage, do not drop the device and do not put heavy objects on top of it. In case of any sign of defect (smoke, sparks or specific smell) unplug the device immediately and contact a Stardex service center. All cables included in the delivery kit are supplied with standard plugs and must not have any mechanical damage. Opening the covers and doors of the device during operation is strictly prohibited! Keep and use the device in areas inaccessible for children and pets. The device is designed to work with Common Rail system. The user must understand structure and working principle of CR injection systems. Incorrect use of the device may cause the damage of the device or injury of the operator.

3 2. Technical requirements and operation directions European version of the device Dimensions AC power supply Power consumption in stand-by mode Power consumption in full load mode Operating temperature Relative humidity 1000х620х1530 mm 400 V 3-Phase 90 W Up to 4 kw From С to С No more than 90% at 25 0 С 3. General description. Stardex 0601 is a highly professional universal device for testing Common Rail diesel injectors of different models and manufacturers. Stardex 0601 is reliable and easy to use. The injector test procedure is fully automated and does not require any special operator skills. Stardex 0601 contains in its database more than 1000 test plans for automated testing of Bosch, Delphi, Denso, Siemens, and Caterpillar Common Rail injectors. The device is equipped with an electronic flow meter that quickly and accurately measures delivery and back flow of injectors and automatically fill up summary table with the measurement results. All you need to do is to install the injectors on Stardex 0601, choose manufacturer from the list, put in part number of injectors to be tested, and push only one button to start the test. After the test is performed, the system provides a detailed report about tested injectors. There is Manual mode for advanced users, when the operator can vary pump rotation speed, pulse width, pressure in the fuel rail and change measuring units of the flow meter. Operator can create and maintain his own test plans. Device is capable of producing pressures up to 1700 bar. Protection shield made of transparent plexi-glas covers the working area, protecting personnel from possible accidents caused by high-pressure.

4 The device designed for testing Common Rail injectors manufactured by Bosch, Delphi, Denso, Siemens, Caterpillar and others, both piezo and electromagnetic. The device can test from one up to four injectors. It works both with electromagnetic and piezo Common Rail injectors. It is possible to check electromagnetic coils of injectors 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 (not included).

5 4. Installation and connection Release the test bench from package materials and mount it on the floor. Distance between the wall and back panel of the device must not be less than 30 cm. Set the control unit Stardex 0303 inside the housing of the test bench as shown on the picture below. Connect keyboard and mouse to the control unit. If you use external monitor, connect it to the device. Remove the upper back panel of the test bench. To unlock it use key, included in the delivery kit.

6 Connect required cables to the corresponding connectors on the rear panel of control unit Stardex 0303 as shown on the pictures below.

7 Remove the front cover of the test bench. To unlock it use key, included in the delivery kit. Make sure there are no visible damages of the equipment, fuel lines or electrical wires, which might be sustained during transportation. Fill the tank with calibration oil. Turn on the power switch, located on the rare panel of control unit Stardex Close front and rear covers of Stardex 0601 test bench. 5. Switching on\off the device Connect device to the 400V power line. Switch on the main circuit breaker, located on the left panel.

8 Start loading the operating system by pressing power button on the front panel of Stardex 0303 After booting the operating system the device is ready for use. To turn off the device, press power button on the front panel of control unit Stardex When the LED on the front panel turns red switch off power circuit breaker. Power switch Pressure sensor cable socket Display input for front panel monitor Power cable socket Injector cable socket Video output USB ports Navigation Power button Mode Plot Menu Navigation Select Start Stop

9 6. Interface description CR injector testing Tested injector type Pulse width Test mode indicator button Target pressure indicator Real pressure Start/stop button (pressure) Pulse frequency Start/Stop button (injector) S/N select button Information window Injectors select buttons Set cycles count Status indicator Information line Result button Previous/next buttons Report button Test mode indicator button changes test mode. Injector CR injector testing according to test-plan, step by step in semiautomatic mode. Manual CR injector testing without test plan with user s parameter settings. Auto CR injector test according to the test plan, in automatic mode The inscription on the indicator button corresponds to the selected test mode. Injector S/N select button opens manufacturer serial number selection window of tested pump or injectors depending on selected test mode. Information line displays the manufacturer and serial number of tested injectors. Information window describes the user s step by step actions during injectors testing (testplan).

10 Result button opens report chart for entering the values of measured parameters in the report, when test performed in manual and semiautomatic mode. <<< and >>> buttons are used to switch between different test steps in information window. Report button displays a full report on the results of injectors testing. Real pressure indicator shows pressure sensor readout. Start\ Stop Button (injector) button starts and stops activation of injectors being tested, with signal of set width and frequency. Start\ Stop Button (pressure) turns on and off pressure control in fuel rail. When START is pressed, installed at fuel rail PCV (pressure control valve) is controlled in such a way that real pressure in rail reaches the level of set target pressure. When stop is pressed, there is no signal to PCV. Injectors select buttons give the possibility to choose and activate selected injectors. Figures on the buttons correspond to the numbers on cables. Status indicators have 3 states: Indicator is green - injector is selected for testing. Indicator blinks in green injector activated, the signal is being sent to the injector. Indicator is red - injector is not selected for testing.

11 Current plot Current scale Check box Time scale Refresh button Change Mode 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 (ZOOM) button zoom the graph in the beginning of pulse. Pressing the button for the second time returns to default view.

12 Menu Pressure sensor type Max pressure reset time Plot auto refresh time Connection status Quit to system View customization Software version Pressure sensor type the user sets parameter according to the type of pressure sensor, connected to device. 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). Connection status indicator Connected device is recognized, connection established Disconnected devise is not recognized, no connection. Software version the current version of the software installed on Stardex VIEW button opens display configuration and interface settings menu. Quit to system quit to operating system.

13 Test bench mode menu Real pressure Target RPM Real RPM Real temperature Supply pump Start rotation Common stop Target RPM control Target temperature control Test bench systems status Target temperature Real RPM the rotation speed of the test bench high pressure pump, measured in revolutions per minute. Target RPM When ROTATE START button is pressed, test bench automatically maintains the rotational speed of high pressure pump at the set target speed, until UNIT STOP button is pressed. Target RPM control buttons increase or decrease the target RPM on 100 or 10 RPM. Real temperature temperature of the calibration oil in the tank, measured in degrees Celsius. Target temperature test bench automatically maintains the temperature upper limit of the calibration oil in the tank at the set target temperature. Target temperature control increase or decrease the target temperature by 1 degree Celsius. Real pressure - readings from the pressure sensor in the fuel rail.

14 UNIT STOP button stops the rotation of pressure pump, reduces the pressure in rail to a minimal level and stops activating the injectors. Use Pump press and hold this button to activate low pressure supply pump to fill in the lines of low pressure circuit. 7. Installing injectors on Stardex Open the protective cover. Make sure that the pressure regulator and the rail pressure sensor connected respectively to the Regulator and Sensor connectors of Stardex 0303 control unit. Make sure that the high pressure hose, connecting the outlet of high-pressure supply circuit with the inlet of fuel rail is not damaged and installed properly. Unscrew the plugs on the rail and install in their places high pressure hoses with injectors as shown on the picture below. Make sure that high pressure hosess are not damaged. Vacant outputs of the fuel rail must be closed with plugs. Install diagnostics adapters on the nozzles of injectors. Connect the diagnostics adapters to the appropriate Delivery inlets, using high pressure hoses included in the delivery kit. Install special adapters on injectors backflow outlets and connect them with appropriate test bench Recovery inlets. Connect the injectors to the test bench Injectors connector using the appropriate cable included in the delivery kit. 8. Injector test in Auto mode Turn on the test bench and control unit Stardex Install injectors on the test bench. Select Bench tab in Stardex 0303 and set Auto mode. Choose the connected injectors by injector select buttons according to the numbered cables. Select manufacturer and serial number of the tested injectors. Start automatic test by pressing START button in menu. Test bench Stardex 0601 will perform all the steps from the test plan, without further human intervention, it automatically sets required pump speed, pressure in the rail and required signal to the injectors. Values obtained for the delivery and recovery of each

15 injector are automatically included in the results table. The range of possible values for each test is highlighted in gray. The satisfying results of the test plan will be marked in green, poor results marked red. Press print button to print out test results. 9. Injector test in Injector mode Turn on the test bench and control unit Stardex Install injectors on the test bench. Select Bench tab in Stardex 0303 and set Injector mode. In Stardex 0303 on-screen menu select the connected injectors by injector select buttons according to the numbers on cables. Select manufacturer and serial number of the tested injectors. Follow step by step instructions shown in the information field. While operating the high pressure test bench always close the protective screen to avoid injury in case of high pressure line damage!

16 10. Delivery kit Stardex Stardex Four injectors connection cable for Bosch 1 Four injectors connection cable for Delphi 1 Four injectors connection cable for Denso 1 Four injectors connection cable for Siemens/Bosch 1 Four injectors multisystem connection cable, Type 1 1 Four injectors multisystem connection cable, Type 2 1 Connecting cable for Bosch pressure regulator 1 Connecting cable for Bosch pressure sensor 1 High pressure fuel hose14х1.5 12х1.5 4 High pressure fuel hose 14х1.5 14х1.5 4 Back flow line connectors Bosch 4 Back flow line connectors Delphi 4 Plastic tube, D 6мм 8 м Computer mouse 1 Computer keyboard 1