MSG Equipment MS002 COM User manual

MSG MS002 COM
TEST BENCH FOR DIAGNOSTICS OF ALTERNATORS,
STARTERS AND VOLTAGE REGULATORS
QUALITY UNIQUENESS
INNOVATION TRAININGSERVICE
WARRANTY
2017.05.16
USER MANUAL

2
CONTENTS
1. DESCRIPTION .......................................................................................................................................................3
2. TECHNICAL CHARACTERISTICS.........................................................................................................................4
3. RECEIPT AND INSPECTION.................................................................................................................................5
4. TEST BENCH DESCRIPTION................................................................................................................................5
4.1 Mounting Face...........................................................................................................................................5
4.2 Sockets.........................................................................................................................................................7
4.3 Adjustment Knobs....................................................................................................................................7
4.4 Buttons........................................................................................................................................................8
4.5 Display. Data Output................................................................................................................................9
5. SETTING INTO OPERATION..............................................................................................................................14
5.1 Connection.................................................................................................................................................14
5.2 Starter Testing ..........................................................................................................................................14
6. STEP-BY-STEP INSTRUCTION.........................................................................................................................15
6.1 Alternator Testing ....................................................................................................................................15
6.2 Starter Testing ..........................................................................................................................................16
6.3 Voltage Regulator Testing.....................................................................................................................16
7. TEST CERTIFICATE...............................................................................................................................................17
APPENDIX 1 ................................................................................................................................................................18
APPENDIX 2 ................................................................................................................................................................20
APPENDIX 3 ................................................................................................................................................................23
User Manual - Test Bench MSG MS002 COM

3
User Manual - Test Bench MSG MS002 COM
1. DESCRIPTION
Test Bench MSG MS002 COM is a high power multifunctional test bench. The equipment includes
the following diagnostic functions: testing of starters, alternators and voltage regulators without
applying any additional measuring devices.
The test bench was invented on the basis of the requirements of modern service stations: con-
struction implies mounting of majority of units without using additional fixing elements. The test
bench tests units of 12V and 24V; diagnoses the latest alternators and voltage regulators, which are
controlled by car ECU; it has ports to connect alternators of different brands and manufacturers:
«COM» («LIN», «BSS»), «P-D», «DFM», «D+», «RLO», «C», «SIG».
Diagnostics is carried out through load simulation of car consumers, change of rotation speed,
sending of control signals (external control alternators), tracking of electrical characteristic. Testing
results are transmitted to LCD display real-time.
Testing modes are switched with membrane keyboard on the control panel of the test bench. The
selected mode is lightened with the corresponding indicator.
Fig. 1. MS002 COM - Front view

4
2. TECHNICAL CHARACTERISTICS
Supply voltage, V 380±10%
Supply type Three-phases
Battery model (not concluded in the set) Any, up to 60 A*Hr
Battery charge 1 Уеs
Battery charge 2 No
Dimensions, mm (length, width, height) 550*440*1000
Weight, kg 125
Testing of alternators
Voltage, V 12/24
Drive power, kW 5.5
Load 12V / 24V, А 0-200/0-100
Load adjustment Smoothly
Drive rotation, rpm 0-3000
Drive rotation direction Both directions
Transmission type (drive/alternator) Belt
Belt type V belt
Poly-V belt
Connection terminals COM (LIN, BSS), P-D, DFM, D+,
RLO, C, SIG, F
Read parameters
- Voltage
- Alternating current
- Constant current
- Drive rotation
- COM voltage regulators: protocol,
speed of exchange, protocol type, errors
Testing of starters
Voltage, V 12/24
Power, kW Up to 4
User Manual - Test Bench MSG MS002 COM

5
User Manual - Test Bench MSG MS002 COM
Check the set received. It must contain:
• test bench
• wires to connect an alternator, starter, voltage regulator to the bench sockets
• User Manual
3. RECEIPT AND INSPECTION
Measured parameters
- Voltage
- Alternating current
- Constant current
Testing of voltage regulators
Voltage, V 12/24
Tested parameters
- Stabilizing voltage
- Current through rotor winding
- COM voltage regulators: protocol,
speed of exchange, protocol type, errors
Voltage meter accuracy, V 0.1
Ampere meter accuracy, А 0.1
Short circuit protection Yes
Short circuit sound alert Yes
Connection terminals COM (LIN, BSS), P-D, DFM, D+, RLO, C, SIG
Total check, sec 30 and longer
Inspect the test bench for existence of damage. If it is found, please contact either the manufacturer
or trade representative before launching the equipment.
WARNING! In case of obvious damage, use of equipment is forbidden.
4. TEST BENCH DESCRIPTION
4.1 M F
Mounting face consists of (Fig. 2):
- Chain fixer
- Chain
- Belts

6
User Manual - Test Bench MSG MS002 COM
The chain fixer (1) is used to latch the chain (2).
The belts (3) and (4) are used to transfer engine torque of the bench on a tested pulley of an
alternator.
Fig. 2. MS002 COM - Mounting face
Control panel consists of (Fig. 3):
- Test bench emergency button
- Test bench power button
- LCD screen
- Keypad with LED indicators
- Adjustment Knobs
Fig. 3. MS002 COM - Control panel

7
User Manual - Test Bench MSG MS002 COM
• D+: used for testing alternators and voltage regulators with L, D+, I, IL, 61 terminals.
LAMP indicator (control lamp simulation on instrument cluster) is lightened next to D+ socket.
• DFM: used to control load on an alternator. It is connected to FR, DFM, M voltage regulator
terminals.
• B+: used for positive potential injection to a voltage regulator. It is connected to IG, S, AS, BVS,
A, 15, 30 voltage regulator terminals.
• GC: used to test alternators with COM, P-D, RLO, C, SIG, 67 terminals.
• В-: used for negative potential injection to a voltage regulator.
• St: used for simulation of rotor winding terminals of an alternator in the mode of testing a
voltage regulator.
• FLD: used to connect voltage regulator brushes or terminals corresponding to the sockets.
• 50: used to test starters. Starter solenoid terminal is connected.
4.2 S
• REGULATION GC: the knob to adjust generation voltage of an alternator or stabilizing voltage
of a voltage regulator. It is used to connect a voltage regulator or alternator to GC socket. The set
voltage parameters reset on short pressing.
• ELECTRICAL LOAD: the knob to adjust electrical load on an alternator (simulates car
consumers). The set load parameters reset on short pressing.
• ROTATION SPEED: the knob to adjust drive rotation and rotation direction. The drive stops and
electrical load parameters reset on short pressing.
4.3 A K
Inspect the test bench for existence of damage. If it is found, please contact either the manufacturer
or trade representative before launching the equipment.
Fig. 4. MS002 COM - Adjustment Knobs

8
• Alternator & starter tester: on/off switch of the
testing mode of starters and alternators. The button is
lightened in active mode with option to choose voltage
and connection to an alternator.
• 12V/24V: buttons to set voltage for testing starters
and alternators. The button is lightened when the
voltage is set.
• Voltage regulator tester: on/off switch of the
testing mode of voltage regulators. The button is
lightened in active mode with option to choose voltage
and connection to a voltage regulator.
• P-D: sends signal to GC connection port to check
alternators with P-D terminal.
• С: sends signal to GC connection port to check
alternators with С terminal.
• RLO: sends signal to GC connection port to check
alternators with RLO terminal.
• SIG: sends signal to GC connection port to check
alternators with SIG terminal.
• СОМ: sends signal to GC connection port to check alternators with СОМ terminal.
• F(67): sends potential to GC connection port to check alternators without voltage regulators.
Voltage is regulated by plus.
• START: on/off switch of positive potential through 50 connection port to gate terminal of
starter solenoid.
• Test bench emergency stop button.
• Test bench on/off switch button.
4.4 B
User Manual - Test Bench MSG MS002 COM
Fig. 5. MS002 COM - Control panel

9
User Manual - Test Bench MSG MS002 COM
• REGULATION GC: ensures adjustment of output parameters of a voltage regulator, used when a
voltage regulator is plugged into GC connection port. Parameters reset after a short pressing.
• ELECTRICAL LOAD: the knob for adjusting electrical load on an alternator (simulates vehicle
electrical consumers). Parameters reset after a short pressing.
• RPM: the knob for adjusting drive rotation. Sets direction (to the left/right) and speed of the
drive.
The drive stops and parameters reset after a short pressing.
Voltage regulator tester mode ensures switching of testing windows on the display.
4.5 D. D 
• VOLTAGE, DC: generation voltage indicator (alternator testing) or consuming voltage indicator
(starter testing).
• DFM, %: indicator of load on an alternator.
• AMP, DC: constant current indicator. Generation indicator (alternator testing) or consuming
voltage indicator (starter testing).
• AMP, AC: alternating current indicator.
• TACHOMETER: drive rotation indicator. It is not used when testing a starter.
• D: indicator of set generation voltage when testing alternators with P-D terminal (Fig. 6).
• P: stator winding frequency indicator when testing alternators with P-D terminal (Fig. 6).
• С: indicator of set generation voltage when testing alternators with С terminal (Fig. 8).
• RLO: indicator of set generation voltage when testing alternators with RLO terminal (Fig. 9).
• SIG: indicator of set generation voltage when testing alternators with SIG terminal (Fig. 10).
• PROTOCOL: voltage regulator protocol indicator (alternators with COM terminal only) (Fig. 11)
• BAUD: indicator of data exchange speed indicator of a voltage regulator (alternators with COM
terminal only) (Fig. 11).
• COM: indicator of set generation voltage when testing alternators with COM terminal (Fig. 11).
• ID/TYPE: ID and voltage regulator type indicator (alternators with COM terminal only) (Fig. 11).
• ERROR: voltage regulator error indicator (alternators with COM terminal only) (Fig. 11).
• VOLTAGE REG: indicator of set generation voltage (alternators without a voltage regulator only)
(Fig. 12).
Display Data Output when Testing an Alternator or Starter
Display Indicators

10
Fig. 6. Display data output when
testing an alternator with D+
terminal or a starter
Fig. 7. Display data output when
testing an alternator with
P-D terminal
Fig. 8. Display data output when
testing an alternator with
С terminal
Fig. 9. Display data output when
testing an alternator with
RLO terminal
User Manual - Test Bench MSG MS002 COM

11
User Manual - Test Bench MSG MS002 COM
Fig. 10. Display data output when
testing an alternator with
SIG terminal
Fig. 11. Display data output when
testing an alternator with
COM (LIN, BSS) terminal
Fig. 12. Display data output when
testing an alternator without a
voltage regulator F(67)

12
• VOLTAGE, DC: stabilizing voltage indicator of a voltage regulator.
• DFM,%: indicator of load on a voltage regulator.
• AMP, DC: indicator of constant current through winding of simulated rotor.
• D: indicator of set stabilizing voltage of a voltage regulator (voltage regulators with P-D terminal
only) (Fig. 14).
• P: stator winding frequency indicator of a voltage regulator (voltage regulators with P-D terminal
only) (Fig. 14).
• С: indicator of set stabilizing voltage of a voltage regulator (voltage regulators with C terminal
only) (Fig. 15).
• RLO: indicator of set stabilizing voltage of a voltage regulator (voltage regulators with RLO
terminal only) (Fig. 16).
• SIG: indicator of set stabilizing voltage of a voltage regulator (voltage regulators with SIG terminal
only) (Fig. 17).
• PROTOCOL: voltage regulator protocol indicator (voltage regulators with COM terminal only)
(Fig. 18).
• BAUD: indicator of data exchange speed indicator of a voltage regulator (voltage regulators with
COM terminal only) (Fig. 18).
• COM: indicator of set stabilizing voltage of a voltage regulator (voltage regulators with COM
terminal only) (Fig. 18).
• ID/TYPE: ID and voltage regulator type indicator (voltage regulators with COM terminal only)
(Fig. 18).
• ERROR: voltage regulator error indicator (voltage regulators with COM terminal only) (Fig. 18).
Display Data Output when Testing an Alternator or Starter
Display Indicators
User Manual - Test Bench MSG MS002 COM

13
User Manual - Test Bench MSG MS002 COM
Fig. 13. MS004COM
Display data output when testing a voltage
regulator with L/D+ terminal
Fig.14. MS004COM
Display data output when testing a voltage
regulator with P-D terminal
Fig. 15. MS004COM
Display data output when testing a voltage
regulator with C terminal
Fig. 16. MS004COM
Display data output when testing a voltage
regulator with RLO terminal

14
Fig. 17. MS004COM
Display data output when testing a voltage
regulator with SIG terminal
Fig. 18. MS004COM
Display data output when testing a voltage
regulator with COM terminal
User Manual - Test Bench MSG MS002 COM
5. SETTING INTO OPERATION
5.1 C
Install the bench in the premises with temperate humidity and temperature. Unscrew the bolts
and open the battery box cover of the test bench. Connect the batteries to the relevant wires, as
indicated on the terminal posts.
Battery 1 and Battery 2 terminal posts must comply with the corresponding battery.
Link the test bench to a single-phase mains supply.
WARNING! Use a specified battery type only.
WARNING! Observe polarity of the terminal posts, otherwise, may cause failure of the test
bench. In this case a customer loses warranty package, provided by the manufacturer.
WARNING! Make sure that mains voltage corresponds to the technical data of the test bench.
5.2 S  P M
It is strongly recommended to learn actual User Manual before launching the bench.
Make sure that the test bench is disconnected from mains supply before running any maintenance
procedures.
Make sure that the batteries are permanently charged.

15
User Manual - Test Bench MSG MS002 COM
6. STEP-BY-STEP INSTRUCTION
Before testing the unit, make sure that all bolts are tightened, the test bench is not damaged and
has no cracks. 6.1 A T
• Install the unit must on the mounting face.
• The pulley must align with the belt.
• Release the chain to the required length (by pressing the button Chain release on the control
panel), latch the chain over the chain fixer (1) of the mounting face.
• Fix the unit on the mounting face (by pressing the button Tighten chain on the control panel).
Tightening will stop automatically.
• Release the belt to the required length (by pressing the button Belt release), latch the belt over
an alternator pulley. Tighten the belt (by pressing the button Tighten belt) until tension of the belt
is the same as in the car. Belt tension is set manually. Belt tension stops by pressing the button
Tighten belt one more time.
• Connect the power cable (Fig. 2) B- with multi-functional tightening, called ‘crocodile’, to the body
of the tested unit, which is earth, connected to negative terminal of the battery.
• Press the button Alternator & Starter tester, set required voltage with 12V/24V buttons, according
to the technical characteristics of a tested alternator.
• Connect B+ wire (Fig. 2) to the power terminal of an alternator.
• Connect terminals of a voltage regulator to the corresponding sockets of the test bench.
• Press the button of the corresponding terminal on the control panel, according to the connection
terminal of an alternator.
• Rotate the adjustment knob ROTATION SPEED to the left or to the right, depending on rotation
direction of an alternator. Mostly alternators rotate to the left.
• Faultless alternator starts power generation from 700 to 850 drive rotation.
• If voltage regulator connection terminals are P-D, С, RLO, SIG, СОМ, F(67), set preliminary generation
voltage with the adjustment knob REGULATION GC from 13.5V to 14.5V.
• Reach 3 000 rpm maximum drive rotation.
• Increase the load on an alternator. Rotate the adjustment knob ELECTRICAL LOAD clockwise;
anticlockwise rotation decreases the load.
• If voltage regulator connection terminals are L or D+, generation voltage must not go lower than
13.5V under maximum load, and must not go higher than 14.5V under minimum load.

16
User Manual - Test Bench MSG MS002 COM
WARNING! Generation voltage must correspond to the technical data of a tested alternator.
WARNING! Discharged batteries may consume up to 50 A of generated current.
On finishing testing of an alternator:
• Reset the set load by short pressing the adjustment knob ELECTRICAL LOAD.
• Stop the drive by short pressing the adjustment knob ROTATION SPEED.
• Deactivate testing mode with Alternator & starter tester button.
• Disconnect the wires from an alternator.
• Release the drive belt.
• Release the fixing chain.
• Remove an alternator from the mounting face.
6.2 S T
• Install a starter on the mounting face.
• Release the chain to the required length, latch the chain over the chain fixer of the mounting face.
• Fix the unit on the mounting face. Tightening will stop automatically.
• Connect the power cable B- with multi-functional tightening, called ‘crocodile’, to the body of the
tested unit, which is earth, connected to negative terminal of the battery.
• Press the button Alternator & Starter tester, set required voltage with 12V/24V buttons, according
to the technical characteristics of a tested starter.
• Connect B+ wire to the power terminal of a starter.
• Connect 50 socket to the power terminal of starter solenoid.
• Press START button. A faultless starter will switch on at once.
• Follow the indicators of current and voltage characteristics.
On finishing testing of a starter:
• Deactivate testing mode with Alternator & starter tester button.
• Disconnect the wires from a starter.
• Release the fixing chain.
• Remove a starter from the mounting face.
6.3 V R T
Connect a voltage regulator to the test bench by 2 ways:
1) Connect a voltage regulator to the corresponding outputs of the bench the same way it is

17
User Manual - Test Bench MSG MS002 COM
connected to an alternator.
2) Connect a voltage regulator according to APPENDIX 3.
WARNING! When testing 24V voltage regulators, battery 2 is not used.
T P:
• Activate the testing mode of a voltage regulator by pressing Voltage regulator tester button.
• Set required voltage of a tested voltage regulator with 12V/24V buttons.
• Connect a voltage regulator to the test bench sockets in the following order: В+; B-; D+ and/or
GС; FLD (both brushes); St.
Voltage indicators of faultless voltage regulator ranges from 13,8V to 14,7V.
• If voltage regulator connection terminals are P-D, С, RLO, SIG, СОМ, set preliminary stabilizing
voltage with the adjustment knob REGULATION GC from 13.5V to 14.5V. Stabilizing voltage must
correspond to the set voltage.
Test Bench MSG MS002 COM for diagnostics of starters, alternators and voltage regulators meets
technical requirements of Directive 2014/30/EU - Electromagnetic Compatibility (EMC) EN Directive
2014/35/EU- Lowvoltage(LVD)Directive2006/42/EC-Machinery(MD) andis qualifiedfor exploitation.
7. TEST CERTIFICATE

18
Symbols Functional purpose Connection
B+ Battery (+)
B+
30
A
(Ignition) Input for switch startingIG
15
AS Alternator Sense
BVS Battery Voltage Sense
S(Sense) Input for voltage
comparison at control point
B- Battery (-) B-
31
E (Earth) Earth, battery (-)
D+ Used for connection to an indicator lamp that transfers initial driving
voltage, and indicates alternator operability
L/D+
I Indicator
IL Illumination
L(Lamp) Output for alternator operability indicator lamp
61
FR (Field Report) Output for load control on an alternator
by engine management block
DFM
DFM Digital Field Monitor
M Monitor
LI (Load Indicator) Same as FR, but with universal signal
D(Drive) Input of voltage regulator control with terminal P-D Mitsubishi
(Mazda) and Hitachi (Kia Sephia 1997-2000) D
D(Digital) Input of code voltage installation
on American Ford, same as SIG SIG
RC (Regulator Control) same as SIG
SIG (Signal) Input of code voltage installation
Connection Terminals of Alternators
APPENDIX 1
User Manual - Test Bench MSG MS002 COM

19
User Manual - Test Bench MSG MS002 COM
RVC(L) (Regulated Voltage Control) Similar to SIG, but voltage change ranges
from 11.0 V to 15.5 V. Control signal is sent to L terminal
C(Communication) Voltage regulator input to control engine operation
block. Japanese cars C
G
RLO (Regulated Load Output) Input to control stabilizing voltage with range
from 11,8 to 15 V (TOYOTA) RLO
COM
(Communication) General term for physical interface, alternator control
and diagnostics. Protocols of use: BSD (Bit Serial Device), BSS (Bit
Synchronized Signal) or LIN (Local Interconnect Network) COM
LIN Direct indication on control interface and alternator diagnostics,
con- ducted under protocol LIN (Local Interconnect Network)
DF
Voltage adjustment output F67
F
FLD
67
P
Output of one of alternator stator windings. Used for measuring
alternator driving voltage
S
STA
Stator
W(Wave) Output of one of alternator stator windings for connection of
tachometers in diesel engine cars
N
(Null) Output of average stator winding point. Usually used to regulate
alternator operability with mechanically regulated voltage
by an indicator lamp
D (Dummy) Blank, no connection, mostly in Japanese cars
N/C (No connect) No connection
Options of LRC
voltage regulators
(Load Response Control) Function of voltage regulator response delay
on load increase on an alternator. Delay duration ranges from 2,5 to 15
seconds. On increasing the load (lights, cooler fan on), a voltage regula-
tor adds driving voltage smoothly, ensuring stability of engine drive
rotation. Remarkably seen under idle running

20
Sockets of Alternators
Denso
Bosch
APPENDIX 2
User Manual - Test Bench MSG MS002 COM