COMMON RAIL INJECTOR TESTER

STARDEX 0401

1. Security information
Read the instructions carefully before using Stardex 0401 (the device).
The device must be connected only to AC 220V with 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 the
structure and working principle of injection systems.
Incorrect use of the device may cause the damage of the device or users injury.

2. Technical requirements and operation directions

Dimensions
AC power supply

427.5 351 141.5 mm

220V 50Hz

Power consumption in stand by mode

60 W

Power consumption in full load mode

300 W

Operating temperature
Relative humidity

from -100 to + 500

no more than 90% at 250

3. General Description
STARDEX 0401 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 one Common Rail injector both on the hand pump and on the test
bench.
It works both with electromagnetic and piezo Common Rail injectors.
Stardex 0401 combined with hand pump makes express diagnostics of Common Rail
injectors according to the following parameters: efficiency, leakage, the quality of injection,
the pressure in the beginning of injection.
The device is controlled by navigation buttons on the front panel. All information is
displayed on LCD screen.

4. Switching on/off the device. Connectors and control buttons.

Pressure sensor
connector

Power switch

Fuse holder
Injector cable
connector
Power cable
connector

Select
Start/
Stop
Increase/decrease of
pulse frequency

Increase/decrease of
pulse width

1) Plug the device in AC 220 V 50 Hz outlet with the power cable from the delivery kit.
2) Connect pressure sensor and pressure sensor connector on the back panel with the
cable.
3) Connect injector to injector cable connector with cable using the appropriate
adaptor. Connect the other side of cable to injector cable connector on the back
panel of the device.
4) Press power switch button on the back panel to turn on power unit.
5) To turn off the device press power switch button on the back panel.

5. Interface Description
Nominal
pressure

Tested injector
type

Maximal
pressure

Pulse width

Leakage
Pressure
sensor type

Pulse
frequency

Tested injector type the mode determined by Common Rail injector type :

Bosch electromagnetic injectors Bosch.

Delphi electromagnetic injectors Delphi.
Denso electromagnetic injectors Denso.
Siemens piezo electric injectors Siemens.
Piezo Bosch piezo electric 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 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.
Select button with a short press changes the type of the tested injectors, with a long
press changes the type of pressure sensor.
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 shouldnt be leakage in different connecting points of hand
pump and fuel line!
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 last 5 seconds.
Pressure sensor type user sets this parameter according to the pressure sensor type to
which is connected to the device. To change this parameter press and hold Select button
for a few seconds.

6. Common Rail injector testing on hand pump (express

diagnostics)
Switch on Stardex 0401. Install Common Rail injector on hand pump and ensure that all
connections are sealed. Connect injector to Stardex 0401 using universal cable with a
suitable cap. Connect Stardex 0401 to pressure sensor of one injector fuel rail which is
installed on a hand pump. Select tested injector type using SELECT button. Select pulse
width and frequency using WIDTH and FREQUENCY buttons. Press Start \ Stop to start the
injection. Using hand pump, create the pressure in the fuel line. Measure the pressure in
the beginning of injection. Press Start\Stop button to stop the injection. With the help of
hand pump 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 automatically
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 diagnostics 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 with 1200 microseconds 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 and Piezo Bosch

170 bar 25 bar

These reference materials are not appropriate for all Common Rail injectors, but only for
the most of them!
It is important to know that all Common Rail injectors taken from one engine, must 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 Common Rail injectors on the test bench using

Stardex 0201 and Stardex 0401
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 injector to fuel rail with high pressure tube.
Delivery and return flow of injector connect to measuring unit (ex. Measuring unit of the
test bench). Connect pressure sensor of fuel rail to Stardex 0201. Connect pressure
regulator of fuel rail to the fist channel of Stardex 0201. Connect Stardex 0401 to
the injector with appropriate cable from delivery kit. Turn on Stardex 0201 and Stardex
0401. Enter first channel configuration in Stardex 0201 menu and select Bench Mode.
Select injector manufacturer in Stardex 0401. Control the pressure in the fuel rail using
Stardex 0201, control the pulse to the injector with the help of Stardex 0401.

Conceptual connection pattern

While working at the high pressure test bench, use the protective clothes, to avoid injury
in case of emergency situations!

8. Diagnostics of mechanical injectors on hand pump

Install mechanical injector on hand pump and ensure that all connections are sealed.
Connect Stardex 0401 to fuel pressure sensor of one injector fuel rail which is set on hand
pump. With the help of hand pump create the pressure in the fuel line enough to open the
injector nozzle. Maximal pressure fixed by the device will be injector opening pressure.
To get the exact value of the injector opening pressure, move the handgrip of hand pump
a few times!

9. Delivery kit
Injector tester Stardex 0401

1 piece

Power cable

1 piece

Universal cable for express diagnostics

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 for connection to Bosch pressure sensor

1 piece

One injector fuel rail

1 piece

Pressure sensor

1 piece

Technical Description

1 piece

10. 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.

11. Shipping details.

The product is packed into bubble wrap and carton box.
Weight 5.5 kg.
Length 320 mm.
Width 220 mm.
Height 180 mm.

MANUFACTURED BY:
OY STARDEX LTD
PULTTITIE 2
00880 HELSINKI
FINLAND
+358 (0)44 5523130
www.stardex.fi