MSG MS005 Test Bench for Diagnostics of Alternators and Starters User Manual

: June 8, 2024
: MSG

Table of Contents

INTRODUCTION
APPLICATION
SPECIFICATIONS
EQUIPMENT SET
TEST BENCH DESCRIPTION
APPROPRIATE USAGE
- Safety Guidelines
- Installation and connection of test bench
TEST BENCH MAINTENANCE
- Test bench software update
- Cleaning and care
TROUBLESHOOTING GUIDE
RECYCLING
Contacts
Read User Manual Online (PDF format)
Download This Manual (PDF format)

MSG MS005 Test Bench for Diagnostics of Alternators and Starters

INTRODUCTION

We appreciate you have chosen the products of TM MSG equipment. The present user manual consists of the information on the application, supply slip, design, specifications and rules of usage of test bench MS005. Prior to using the test bench MS005 (hereinafter, “the bench”), study the present user manual thoroughly. If required, get the special training at bench manufacturer facilities. Due to the permanent improvements of the bench, the design, supply slip and software are subject to modifications that are not included to the present user manual. Pre-installed bench software is subject to update. In future, its support may be terminated without a prior notice.

APPLICATION

The bench is designed to check the technical condition of the automotive alternators with different connection terminals, alternators of system «start- stop» 12V, starters and 12V automotive lead-acid storage batteries. The bench displays the measured parameters in real time oscillographically that allows to see the broad picture of unit operation, and to make more accurate check of unit condition. The diagnostics of automotive alternators takes into account the following criteria:

stabilizing voltage;
control lamp working performance capacity;
displaying of the frequency and FR duty ratio (voltage regulator response); – the AC pulsation value.

Additionally for COM alternator types:

ID;
protocol;
data exchange speed;
LIN protocol type;
regulator self-diagnostics errors.

The diagnostics of the automotive starters considers the voltage changes nature and the currents on the terminals 30, 45 and 50 during the starter operation.

SPECIFICATIONS

Main

(not included into supply slip)

C JAPAN, COM (LIN, BSS), «S/A PSA»

24V| Lamp, COM (LIN)
Starter diagnostics
Power of diagnosed starters, kW| up to 11
Measured parameters| The charts displaying the operation starting mode, voltage variations and voltage

current on the terminals: К30, К50 и К45

EQUIPMENT SET

The equipment set includes:

Item name	Number of pcs
Test bench MS005	1

MS33001 – a cable with a kit of adapting wires – for the connection to

alternator connector

TEST BENCH DESCRIPTION

Access door to storage battery location.
Working spot.
Protective housing.
Touch screen – to display diagnostic parameters of a diagnosed unit and to control the bench functions.
Control panel.
Pivot wheels with brake.

The working spot (fig.2) consists of the following components:

Alternator drive belts: V-belts and poly V-belts.
Power cables «В+» «В-».
Unit fixing chain.
The bracket for a diagnostic cable alligator clips.
Thermal vision camera.
Diagnostic cable connection port.
Diagnostic cable connection port for starter diagnostics.

The control panel (fig.3) consists of:

buttons to control the tightening and loosening of alternator drive belt.
buttons to control the tightening and loosening of unit fixing chain.
button «COVER» – opens the protective housing.
button «OFF/ON» – is responsible for the power on the bench. The bench is turned off by pressing the button «Turn off the bench» in the main menu of 1the service program.
Button «EMERGENCY STOP» – emergency stop of generator drive and chain/belt tightening.

In the bottom of the touch screen there are two USB ports (fig.4 ref. 1) for connecting the computer periphery (mouse, keyboard, WiFi adapter) and network LAN port (ref. 2).

The bench supply slip includes the diagnostic cable (fig.5) that consists of the adapting wire kit (fig.6) – for more convenient connection to alternator connection terminals

The diagnostic cable MS-33001 has the following adapting wire color codes (see also Table 1):

Orange – S (Sense Pin) – the terminal that enables the measuring of the storage battery voltage by the voltage regulator as well as it compares the storage battery voltage with the alternator output voltage. This adapting cable is connected to terminal S;
Red – IG (Ignition) – the terminal is used for the connection of the ignition circuit, the terminals: 15, A, IG;
White – «FR» – the terminal that transmits the data on the regulator load. This adapting wire is connected to the following terminals: «FR», «DFM», «M»;
Gray – «D+» – the terminal for the connection of the circuit of voltage regulator control lamp. It’s connected to the terminals: «D+», «L», «IL», «61»;
Yellow – «GC» – is used for the connection of the channel of alternator voltage regulator control. This adapting wire is connected to the following terminals: «COM», «SIG», etc.
Brown – «К30» – is connected to the starter terminal 30 that is connected to the storage battery terminal «+».
Violet – «К45» – is connected to the starter solenoid output connected with starter electric motor.

Table 1 – Color codes of cable MS-33001

Connector	Terminal
S
IG
FR
Lamp
GC
K30 (starter)
K45 (starter)

For convenient usage of the diagnostic cable, it’s recommended to put the alligator clips onto the bracket (ref. 4, fig.2).

For the diagnostics of the starter, use the cable MS-33001 and the cable for the connection of the terminal 50 (fig.8)

APPROPRIATE USAGE

Use the bench for the specified purpose only.
Turning off the bench should be done through the interface of the service program by pressing the “Turn off the bench” button.
Use EMERGENCY STOP button only if you need to immediately stop the bench drive, turn off the belt/chain tightening and turn off the supply of the power cables.
The terminals of the diagnostic cable MS-33001 that are used for the diagnostics of alternators and starters shall be connected only to the relay regulator terminals and starter terminals K30 and K45.
To protect the touch screen from damages use the stylus (included to supply slip).
In case of failures in the operation of the bench, stop further operation and contact the manufacturer or sales representative. The manufacturer is not responsible for any damage or injury to human health resulting from non-compliance with the requirements of this user manual.

Safety Guidelines

The bench has to be operated by the qualified persons who got the access to operate the definite bench types and who were instructed on the safe operating procedures and methods.
The bench has to be turned off if the supply is terminated, during the cleaning and tidying up, as well as in the emergency situations.
The work area must always be clean, with good light illumination, and spacious.
To ensure electrical and fire safety PROHIBITED:
– connect the bench to the electrical network having faulty protection against current overloads or not having such protection;
— use a socket without a grounding contact to connect the bench;
— use extension cords to connect the bench to the electrical network. If the socket is far from the bench installation site, it is necessary to modify the electrical network and install the socket;
– operation of the bench in defective condition.
– Independently to repair and make changes to the design of the bench, because it can lead to serious damage to the bench and deprive the right to warranty repair. 5. It’s forbidden to leave the units with running drive on the bench unattended. 6. While mounting and dismounting of a unit from the bench, to prevent the hands from harming, be more cautious.
Do not open the access door to the bench power section when the bench is connected to the 400V supply circuit.

Installation and connection of test bench

The bench is delivered packed. Release the bench from the packaging materials, remove the protective film from the display (if available). After unpacking, it is necessary to make sure that the bench is intact and does not have any damage. If damage is detected before the bench is activated, contact the manufacturer or the sales representative. The bench has to be placed on the level floor, with the pivot wheels fixed from rotating (min. two wheels) by the activating of the brake mechanism. The bench ensures the operation at the temperature from +100C up to +400C and relative air humidity from 10% up to 75%. When installing the bench, keep the minimum space gap 0.5 m from the rear bench side – for a proper air circulation. Prior to the bench operation, connect: – storage batteries 12V that have to be located in the storage battery section of the bench (fig.9). The left door is opened with the keys (included to the supply slip). While connecting the storage batteries refer to the power cable markings. If only one storage battery is connected just 12V diagnostic mode will be available, 24V diagnostic mode will be unavailable.

electric mains 400V referring to the markings inside the socket (included to the supply slip).

TEST BENCH MAINTENANCE

The bench is designed for a long operation life and doesn’t have any special maintenance requirements. At the same time, to ensure the maximum operation life, the regular monitoring of bench technical condition should be made as follows:

motor operation inspection (uncommon noises, vibration etc.);
alternator drive belts condition (visual inspection);
power wires condition (visual inspection);
inspection of bench operation environment (temperature, humidity etc.).

Test bench software update

Being connected to the Internet, with every switching on, the test bench checks for software updates of diagnostics program, database and bench firmware. In case the bench finds the software update at company server, you’ll be offered to install the update or disregard it. To start updating, press OK, to decline SKIP.
ATTENTION! Updates may take a while to install.
**WARNING!** It’s forbidden to switch off the bench supply to stop the updating.

Cleaning and care

To clean the bench surfaces, use either the soft napkins or rags, and neutral cleansers. The display should be cleaned with a special fiber display cleaning cloth and with a spray for display cleaning. To prevent the bench from the failure and corrosion, do not use abrasive materials and solvents.

TROUBLESHOOTING GUIDE

Below you will find the table with the possible problems and the solutions on their elimination.

Problem	Causes	Solutions
1. The bench doesn’t start.	The automatic switch behind the bench left
door got activated	Open the left door with the key from the supply kit, turn

on the automatic switch to the up position.
The left door is open, the protective terminal switch of the left door got activated| Close the left door.
One of the bench supply phases (L1/L2/L3) or neutral N are lacking| Restore the supply.
2. The bench runs but the electric motor| The variable speed drive software error.| Contact the dealer.
doesn’t start.| The bench wiring is damaged.
3. When the bench runs the abnormal noises are heard.| The diagnosed unit is mounted wrong. (The driving belt is over tightened or out of alignment)| Re-mount the unit for the diagnostics.
4. When the bench runs the abnormal noises are| The belt tightening is not enough| Stop the drive and check the tightening intensity
heard.| The wear of the belt.| Replace the belt.
5. During the alternator test the contact clips heat up much. (alligator clips)| The contact area is small.| Use a positive terminal adapter of the alternator.

RECYCLING

For the recycling of the bench refer to the European Directive 2202/96/EC (WEEE Directive – the directive on waste electrical and electronic equipment).
The outdated electronic devices and electrical appliances, including the cables, hardware, batteries and storage batteries shall be disposed separately from the house waste. To dispose the waste products, exploit the available returning and collecting systems.
The appropriate disposal of the outdated devices helps to prevent harming to environment and health.

Contacts

MSG equipment
HEADQUARTERS AND PRODUCTION
18 Biolohichna st.,
61030 Kharkiv
Ukraine
38 057 728 49 64
+38 063 745 19 68

E-mail: [email protected]
Website: servicems.eu
REPRESENTATIVE OFFICE IN POLAND
STS Sp. z o.o.
ul. Modlińska, 209,
Warszawa 03-120
+48 833 13 19 70
+48 886 89 30 56

E-mail: [email protected]
Website: msgequipment.pl
TECHNICAL SUPPORT
+38 067 434 42 94
E-mail: [email protected]