MSG Equipment MS004 COM User manual

2021.12.10
MS004 COM
TEST BENCH FOR DIAGNOSTICS OF ALТERNATORS,
STARTERS AND VOLTAGE REGULATORS
USER MANUAL
STANOWISKO DO DIAGNOSTYKI ALTERNATORÓW,
ROZRUSZNIKÓW I REGULATORÓW
INSTRUKCJA OBSŁUGI
СТЕНД ДЛЯ ДИАГНОСТИКИ ГЕНЕРАТОРОВ,
СТАРТЕРОВ И РЕЛЕ–РЕГУЛЯТОРОВ
РУКОВОДСТВО ПО ЭКСПЛУАТАЦИИ
UNIQUENESS
TRAINING
SERVICE
NNOVATION
WARRANTY
QUALITY

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CONTENTS
INTRODUCTION....................................................................................................................................................4
1. PURPOSE...........................................................................................................................................................4
2. TECHNICAL CHARACTERISTICS.....................................................................................................................5
3. SUPPLY SLIP....................................................................................................................................................7
4. TEST BENCH DESCRIPTION.......................................................................................................................... 8
4.1. Displayed data.................................................................................................................................... 11
5. APPROPRIATE USE.......................................................................................................................................15
5.1. Safety Guidelines................................................................................................................................15
5.2. Bench pre-starting procedures......................................................................................................15
5.3. Alternator diagnostics ...................................................................................................................... 17
5.3.1. Installation and connection...................................................................................................... 17
5.3.2. Diagnostics....................................................................................................................................19
5.4. Diagnostics of alternator that doesn’t have the integral voltage regulator ..................... 20
5.5. Diagnostics of voltage regulator................................................................................................... 20
5.5.1. Lamp voltage regulator diagnostics.......................................................................................21
5.5.2. P-D, C, SIG, RLO voltage regulator diagnostics....................................................................21
5.3.3. COM voltage regulator diagnostics.........................................................................................22
5.6. Starter diagnostics ............................................................................................................................22
6. TEST BENCH MAINTENANCE.......................................................................................................................23
6.1. Cleaning and care ..............................................................................................................................23
7. TROUBLESHOOTING GUIDE....................................................................................................................... 24
8. RECYCLING ................................................................................................................................................... 26
APPENDIX 1.........................................................................................................................................................27
APPENDIX 2....................................................................................................................................................... 84
APPENDIX 3....................................................................................................................................................... 87

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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 MS004 COM.
The design and software are subject to the modifications by the manufacturer without a prior
notice of users.
Prior to using the test bench MS004 COM (hereinafter, “the bench”), study the present user manual
thoroughly. If required, get the special training at bench manufacturer facilities.
1. PURPOSE
The bench is designed for a quick and a first-class diagnostics of automotive alternators, starters,
and voltage regulators - separate from alternators and starters. The bench is powerful enough to
test the units with a wide load range.
The bench functions as follows:
- evaluates the technical condition and identifies the failed element (unit) of 12/24V alternator of
light motor vehicles and trucks;
- checks the performance capacity of voltage regulator - separate from alternator;
- evaluates the technical condition of 12/24V starters of light motor vehicles and trucks at idle.

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2. SPECIFICATIONS
Main
Supply voltage, V
230 (60Hz) or 120 (50Hz)
Supply type
Single-phase
Drive power, kW
2.2
Dimensions (L×W×H), mm
570×505×450
Weight, kg
70
Quantity of storage batteries
(not included into supply slip) 2 similar lead-acid by 12V
Battery capacity (not included to set)
from 45 up to 60 Ah
Storage battery automatic charging No.1
Available
Storage battery automatic charging No.2
Not available
Rated voltage of the diagnosed units, V
12, 24
Alternator diagnostics
Diagnosed alternator load, A 12V 0-100
24V 0-50
Load adjustment (0-100%) Smoothly
Drive speed, rpm
0-3000
Drive speed adjustment
Smoothly
Drive type (drive/alternator)
Belt
Belt types
- V-belt
- poly V-belt
Types of diagnosed alternators
COM (LIN, BSS), P-D, RLO, C, SIG, F/67
Measured parameters
- Stabilizing voltage;
- Alternating current;
- Continuous current;
- Drive speed;
For COM voltage regulators:
- Protocol;
- Exchange speed;

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- ID;
- Type;
- Errors.
Voltage regulator diagnostics
Types of diagnosed voltage regulators
COM (LIN, BSS), P-D, RLO, C, SIG
Parameters of voltage regulator to be
checked
- Stabilizing voltage;
- Control of the performance capacity of
storage battery indicator lamp circuit (D+)
For COM voltage regulators:
- Protocol;
- Exchange speed;
- ID;
- Type;
- Errors.
Short circuit protection
Available
Short circuit alarm
Available
Starter diagnostics
Power of diagnosed starters, kW
up to 4
Measured parameters
- Voltage;
- Alternating current;
- Continuous current.

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3. SUPPLY SLIP
The supply slip of bench includes:
Description
Quantity, pc.
Test bench MS004 COM
1
MS0109 - wire kit for the connection with voltage regulator
1
Cable for the connection to the external battery
2
Alternator positive terminal adapter
2
MS0114 - Cutout fuse (type 22x58 mm, current 100А)
1
Warning sign stickers (set)
1
User manual
1

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4. TEST BENCH DESCRIPTION
The bench consists of the following main elements (fig. 1):
Figure 1 – Bench main elements
1– Working spot.
2 – Protective housing. When the protective housing is up, the diagnostics will be blocked.
3– Power cables.
4 – Button EMERGENCY STOP - crisis shut down of bench supply.
5 – Button OFF/ON - turns on/off the bench supply. If the button EMERGENCY STOP is pressed,
the button OFF/ON is not active.
6– Control panel.
7– Section for the battery location.
8– Height-adjustable legs.

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The bench is operated from a working spot (fig.2) that consists of:
Figure 2 – Bench working spot
1– Unit fixing chain.
2– Alternator drive belts: V-belts and poly V-belts.
The control panel (fig. 3) consists of the following main elements:
1– Display – diagnostic data displaying.
2– Control panel - consists of the following buttons:
Altenator & starter tester – on/off the mode of diagnostics of alternators and starters;
Voltage regulator tester – on/off the mode of diagnostics of voltage regulator;
12V/ 24V – setting the rated voltage of the diagnosed unit;
P-D, С, RLO, SIG, СОМ – setting the type of the diagnosed alternator;
F/67 – mode of diagnostics of alternator that doesn’t have the integral voltage regulator;
Tighten chain/Chain release – control of tightening/loosening of unit fixing chain;
Tighten belt/Belt release – control of tightening/loosening of alternator drive belt;
START – switching on/off the terminal 50 for the starter start.

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Figure 3 – Bench control panel
3– Diagnostic outputs - for the connection to voltage regulator terminals:
В+ – for connection to terminals: 30, B+, IG, S, AS, BVS, A, 15;
FLD» – outputs - for the connection of the brushes of the voltage regulator at diagnostic mode
of voltage regulator or relevant terminals: DF, F, FLD;
В-– negative (earth, terminal 31);
D+ – input of control lamp of voltage regulator. It’s designed for the connection of the
following voltage regulator terminals: D+, L, IL, 61;
ST – output for the connection to the stator outputs (terminals) of voltage regulator: P, S, STA,
Stator;
GC – output connected to the control terminal of the voltage regulator: COM, SIG, etc.;
FR – alternator load control, connected to: FR, DFM, M;
50 – output connected to the starter terminal 50.
4– Regulators:
REGULATION GC – setting of the alternator output voltage. It’s used when connecting the
alternator to the terminal GC.
ELECTRICAL LOAD – setting of the alternator electric load range (imitates car loads). Press to
smoothly switch off the load down to zero level.
ROTATION SPEED – control of speed and rotation direction of drive. Press to stop the drive.
5– Indicator of control lamp operation.