MSG Equipment MS1000+ User manual

2021.03.19
MS1000+
TEST BENCH FOR SHOCK ABSORBERS
USER MANUAL
STANOWISKO DO DIAGNOSTYKI AMORTYZATORÓW
INSTRUKCJA OBSŁUGI
СТЕНД ДЛЯ ДИАГНОСТИКИ АМОРТИЗАТОРОВ
РУКОВОДСТВО ПО ЭКСПЛУАТАЦИИ
UNIQUENESS
TRAINING
SERVICE
NNOVATION
WARRANTY
QUALITY

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CONTENTS
INTRODUCTION....................................................................................................................................................4
1 PURPOSE............................................................................................................................................................4
2 TECHNICAL CHARACTERISTICS......................................................................................................................5
3 EQUIPMENT SET ...............................................................................................................................................6
4 TEST BENCH DESCRIPTION........................................................................................................................... 8
5 INTENDED USAGE...........................................................................................................................................13
5.1 Safety regulations...............................................................................................................................14
5.2 Test bench installation and pre-starting procedures ...............................................................14
6 TEST BENCH MAINTENANCE ........................................................................................................................15
6.1 Pneumatic clamps oiling...................................................................................................................15
6.2 Bearing unit oiling..............................................................................................................................15
6.3 Puller shaft oiling................................................................................................................................16
6.4 Gear motor inspection and maintenance ....................................................................................17
6.5 Cleaning and care............................................................................................................................... 17
7 MAJOR FAULTS AND RECOVERY TECHNIQUES .........................................................................................18
8 TEST BENCH DISPOSAL ............................................................................................................................... 20

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INTRODUCTION
Thank you for choosing the product by ТМ MSG Equipment.
The actual User Manual contains information on application, technical characteristics, package
contents, design of MS1000+ and all the important details regarding its operation.
The manufacturer reserves the right to make changes to the test bench hardware and software
without prior notice to users.
It is strongly recommended to learn carefully the actual User Manual before putting MS1000+
(hereinafter, “the test bench”) in operation, take special training at the equipment manufacturing
facility if necessary.
Due to the continual improvement of the test bench structure and configuration as well as
firmware upgrade, some changes might not be reflected in this User Manual. The test bench
firmware will require update. Later, firmware support and maintenance can be discontinued
without prior notice to users.
1 PURPOSE
The test bench is designed to assess technical condition of shock absorbers in passenger cars
through taking their force-displacement and force-velocity characteristics.
The test bench for shock absorbers is used to do the following:
•establish whether a faulty unit should be repaired or replaced;
•check on the quality of repair;
•assess the conformity of shock absorber performance to its technical specifications;
•conduct prolonged tests.
A shock absorber can be tested on the test bench both in manual and automatic modes.
The test bench functionality enables the following:
•test all types of passenger car shock absorbers having dumping force up to 1000 kg and
equipped with different mounting mechanisms;
•save test-results;
•compare test results with reference data (before and after repair);
•generate test reports and print them on an external printer.

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2 TECHNICAL CHARACTERSISTICS
Main features
Supply voltage, V
400
Supply type
Three-phase
Drive power, kW
3.7
Dimensions (L×W×H), mm
970×480×2500
Weight, kg
350
Clamp control
Pneumatic
Test bench pneumatic system power
pressure, bar 6
Operating modes
Manual/Automatic
Shock absorber testing
Size of tested shock
absorber
maximum, mm 780
minimum, mm 250
Height adjustment of shock absorber fixing Manual
Shock absorber shaft stroke, mm
Adjustable, from 50 to 150
Shock absorber shaft stroke adjustment
Manual
Bound/rebound maximum load, kg
1000
Frequency of
shock absorber
vibrations
Maximum, min
-1
180
Minimum, min
-1
10
Shock absorber
piston speed (at
50 mm travel)
Maximum, m/s
0.477
Minimum, m/s 0.026
Shock absorber temperature measuring
Yes

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Additional features
Data printout
Yes
Software update
Yes
Connection to the Internet
Wi-Fi (802.11 a/b/g/ac)
Connection of external devices
2 x USB 2.0
3 EQUIPMENT SET
The equipment set includes:
Item name
Number of
pcs
Test bench MSG MS1000+
1
Pneumatic clamp foot control
1
Handle for fixing pneumatic clamp lock nuts
2
2-piece set of changeable fittings for shock absorber
3
Universal prism for fixing shock absorbers with rod end
2
Universal prism for fixing shock absorbers with uncalibrated holes (for shock
absorbers with irregular shafts) 1
Temperature sensor strip
1
Vibration-absorbing pads
4
Wi-Fi module
1
Stylus
1
Set of warning stickers
1
Test bench door key
2
380V socket
1
User Manual
1

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Figure 1. Handles for fixing pneumatic clamp lock nuts
Figure 2. Shock absorber changeable fittings for lower pneumatic clamp (for various types of
shock absorber mounting mechanisms)
Figure 3. Universal prisms for fixing shock absorbers:
1 - universal prisms for fixing shock absorbers with rod ends;
2 - universal prism for fixing shock absorbers with uncalibrated holes (for shock absorbers with
irregular shafts). The prism is a rough work piece which is to be processed (through tapping)
into a special shock absorber lock.

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4 TEST BENCH DESCRIPTION
The test bench consists of the following main components (Fig.4):
Figure 4. Main components of the test bench
1 – mechanical unit;
2 – test compartment where a shock absorber is located during diagnostics;

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3 – display for diagnostic data output and test bench control;
4 – shock absorber nitrogen filling block;
5 – control panel with ON/OFF switch, emergency button, and pneumatic clamp control buttons;
6 – electrical unit;
7 – pneumatic clamp foot control performing the same functions as the respective buttons on the
control panel.
All the operations with the tested shock absorber are carried out in the test compartment (Fig.5)
equipped as follows:
Figure 5. Test compartment
1 – upper pneumatic clamp;
2 – temperature sensor and strip for fastening it to a shock absorber;
3 – lower pneumatic clamp;
4 – lower clamp lock;
5 – rotation wheel for lower clamp height adjustment;

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6 – retainer for lower clamp height adjustment.
A shock absorber is secured inside the test compartment with pneumatic clamps consisting of the
components shown in Fig. 6 and 7.
Figure 6. Components of upper pneumatic clamp:
1 – linear cam; 2 – guide slide block; 3 – slide block; 4 – lock nut; 5 – push rod.
The lower pneumatic clamp is equipped with changeable fittings (Fig.7) for securing shock
absorbers with different mounting mechanisms.
Figure 7. Components of lower pneumatic clamp:
1 – linear cam; 2 – guide slide block; 3 – slide block; 4 – lock nut; 5 – push rod;
6 – socket set screw; 7 – mechanism for shock absorber fixing.

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Control panel buttons (Fig.8):
Figure 8. Control panel
1 – pneumatic clamp control buttons;
2 – EMERGENCY STOP button for emergency power cutoff;
3 – OFF/ON switch for test bench activation/deactivation. OFF/ON switch is inoperative when
EMERGENCY STOP button is pressed.
The rear panel of the screen (Fig.9) contains the following: one LAN network connector for
connection of the test bench to the Ethernet, two USB ports that can be used for connection of
either a Wi-Fi adapter or external printer.
Figure 9. LAN and USB ports

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Shock absorber nitrogen filling block consists of the following components (Fig.10):
Figure 10. Components of nitrogen filling block:
1 – cylinder nitrogen pressure indicator; 2 – supply line pressure indicator; 3 – nitrogen
cylinders; 4 – gear; 5 – filling coupling nitrogen pressure control; 6 – filling coupling.
WARNING! Cylinders with nitrogen are not included in the equipment set.
In the bottom of the test bench rear panel there is a port for a compressed air supply hose (Fig.11,
n.1) and power cord (Fig.11, n.2).
Figure 11. Port for connection of supply hose for compressed air

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Shock absorber stroke adjustment along with some other maintenance operations are carried out
in the mechanical unit of the test bench (Fig.12). The unit includes the following components:
Figure 12. Mechanical unit
1 – position sensor;
2 – puller shaft;
3 – puller stroke adjustment mechanism;
4 – bearing.
5 INTENDED USAGE
1. Use the test bench as intended (see Section 1).
2. Do not carry out any repair work in the test compartment to avoid damage to the test bench.
3. Fix securely a shock absorber in the pneumatic clamps. Any play between the shock absorber
and pneumatic clamp may result in obtaining incorrect test data and damage to the test bench.
4. Do not test the shock absorber known to be faulty.

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5. Use EMERGENCY STOP button (Fig.6, n.2) or OFF/ON switch (Fig.6, n.3) for deactivation of the test
bench in emergency situations only. In normal operation, turn the bench off by clicking on TURN
OFF THE BENCH button on the program interface. When the display goes blank, press OFF/ON.
6. Use stylus (Fig.4, n.3) to preserve the touch screen from damage (included in the equipment
set).
7. The use of computer hardware and software foreign to the test bench will result in warranty
annulment, even in case when these hardware and software have been subsequently removed.
Only genuine MSG Equipment software is allowed for installation.
8. Only a legal manufacturer is allowed to make changes to the test bench. The product can be
used only with genuine spare parts and accessories. Violation of this condition will lead to
warranty annulment.
9. Do not make any changes to the test bench structure to avoid its damage. In case of malfunction,
contact the manufacturer or sales representative.
MSG Equipment shall not be held liable for any loss resulted from improper use of the equipment.
WARNING! The procedure of testing shock absorbers with test bench MS1000+ is described in
the “Operation instruction for diagnostics of shock absorbers” Download it on servicems.eu
under the respective product detail page.
5.1 Safety regulations
1. Only trained and authorized personnel is qualified to operate certain test bench types.
2. It is strictly prohibited to activate the test bench when the doors of mechanical and electrical
units are open. DO NOT open the doors before the expiry of 10 minutes after power off.
3. Avoid dropping a shock absorber during its mounting/dismounting on the test bench.
4. Keep your work space clean, well-illuminated, and spacious.
5. Before testing, make sure the test bench is earthed and in good order. Otherwise the operation
of the test bench is strictly forbidden.
6. Disconnect the test bench from the power supply before starting any maintenance work.
5.2 Test bench mounting and setup
The test bench is delivered in packaging. Unpack the test bench and make sure it has no damages.
Packaging materials are fully recyclable and should be wasted separately from domestic garbage.
Position the test bench upright (use a leveling gauge) on the level floor. When moving the test
bench, do not hold it by its movable or perforated parts. Put vibration-absorbing pads under the
test bench legs.

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Keep the distance of at least 0.5 meters between the test bench and the room walls or any other
objects. The test bench ensures safe operation in the temperature range between +10 °С and
+40 °С and relative humidity of 10-90% (without water condensation).
Before launching the test bench, connect it as follows:
- to 400V power supply line;
- to compressed air source.
6 TEST BENCH MAINTENANCE
СTest bench MS1000+ is intended for long-lasting operation under twenty-four-hour schedule.
However, for trouble-free enduring operation it is essential to inspect the test bench and observe
preventive measures described below with recommended intervals. Inspection and preventive
measures should be carried out by a qualified specialist.
Special attention should be paid to the following aspects of daily inspection:
• Appropriate operation of the motor (no unusual sounds, vibration, etc.).
• Appropriate ambient conditions for the test bench use (temperature, humidity, air pollution,
vibration, etc.)
• Correspondence of supply voltage range to the test bench operation requirements.
Weekly inspection of the test bench must include the following:
• Visual inspection of the bearing unit and puller shaft for traces of oil leaks.
• Check the moving parts of the upper and lower pneumatic clamps for sufficient lubrication.
WARNING! Improper fixing of shock absorbers in pneumatic clamps is the most common cause
of the test bench malfunction.
6.1 Pneumatic clamps oiling
Once a month check the lubrication of wear surfaces of linear cams (n.1, Fig. 6, 7) and glide slide
blocks (n.2, Fig. 6, 7). Litol-24 is a commonly used grease. Other lithium-based greases are also
usable.
Remove visible residue of old grease with a waste cloth before oiling pneumatic clamps. Move the
clamps several times.
6.2 Bearing unit oiling
As the lubricating grease picks up dirt and loses its qualities with time, it should be refreshed
every once in a while. The intervals at which the lubrication should be replaced or refreshed
depend on the severity of use. However, the maximum interval shouldn’t exceed two years. During

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the first two times, lubrication can be refreshed. Subsequently, it must be replaced. Litol-24 is a
commonly used lubricant. Other lithium-based greases are also usable.
To replenish the lubricating oil, use the nipple on the bearing unit (Fig.13) and a special syringe.
Figure 13. Nipple on the bearing unit
Follow the instruction below to oil the bearing unit:
1. Disconnect the test bench form a supply line and wait for 10 minutes.
2. Open the door of the mechanical unit.
3. Remove the cap from the nipple, having it and the adjoining surfaces previously cleaned from
dirt and dust.
4. Use a special syringe to inject grease into the nipple. Continue to pump until you see grease
squeezing out from the bearing.
5. Upon finishing, remove the remaining grease with a cleaning cloth.
6.3 Puller shaft oiling
The lubricant type as well as grease replenishment and changing schedule are similar to the ones
used for bearing unit maintenance (Section 6.1).
Follow the instruction below to oil the puller shaft:
1. Disconnect the test bench form a supply line and wait for 10 minutes.
2. Open the door of the mechanical unit.
3. Clean the grease nipples (Fig.14) and adjoining surfaces from dust and dirt.

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4. Screw off one of the grease nipples.
5. Use a special syringe to inject grease into the nipple. Continue to pump until you see grease
squeezing out from the bearing.
6. Upon finishing, remove the remaining grease with a cleaning cloth. Screw in the grease nipple.
Figure14. Grease nipples on the puller shaft.
6.4 Gear motor inspection and maintenance
Perform the following maintenance procedures:
•every 500 hours of work or every month:
1) Inspect the gear motor visually for possible oil leakage.
2) Remove dust with a vacuum cleaner - the layer of dust accumulated on the gear motor
cannot exceed 5mm thick.
•every 5 years:
Replace synthetic oil. 6.5 Cleaning and care
Use soft tissues or waste cloth to clean the test bench surfaces. Clean the touch screen with a
special fibrous tissue and spray for display screens. Do not use any abrasive materials or solvents
to avoid damage to the screen or corrosion.

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7 POTENTIAL FAILURES AND METHODS OF RECOVERY
Below are the potential faults and recovery methods:
Failure symptom
Possible fault cause
Recovery method
1. When you switch the
test bench on, a three-
pole circuit-breaker is
actuated.
Test bench wiring is damaged.
Contact sales representative.
Too much dust inside the test
bench. Clean the test bench.
2. Unrealistic
dynamogram
indication.
Loose lock nut of force sensor
fixation (pressure sensor). Check force sensor fixation. Adjust if necessary.
Loose fixation of position sensor.
Check position sensor fixation.
Adjust if necessary.
3. Excessive steady
noise emanates from
electrical unit in the
process of test bench
operation.
Damage of gear motor bearings.
Replace bearings.
Foreign particles in oil. Check oil quality. Change oil if
necessary.
4. Motor is on – a gear
input shaft rotates,
while an output shaft
does not.
No engagement in gear. Contact sales representative.
5. Oil leak through
gear cover. Loss of tightness of rubber gasket under gear cover.
Tighten bolts of gear cover
fitting. If leakage continues,
turn to sales representative.
6. Test bench
diagnostic program
load failure.
Test bench operating system
failure.
Contact sales representative.
7. Pneumatic clamps
are out of work.
No pressure in pneumatic line.
Check connection of
compressed air supply.
Condensed water in filter-dryer
of air preparation unit.
Remove filter-dryer plug and
drain condensed water into
prepared container.
8. Asynchronous
operation of left and
right pneumatic clamp
pullers.
Different speed of pneumatic
cylinders filling.
Adjust speed of filling by air
exhaust and air supply
throttles.

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Failure symptom
Possible fault cause
Recovery method
9. Test mode
activation failure.
EMERGENCY button on control
panel is stuck.
Check EMERGENCY button – it
must be in neutral position.
10. Test turnaround
failure. Loose fixation of position sensor.
Check position sensor fixation.
Adjust if necessary.
11. Motor doesn’t
start.
Short circuit of either cable or
motor windings to ground.
Clear a fault. Restart test
bench,
Low power supply voltage.
Make sure there are no high-
power consumers of high
starting current nearby the
test bench.
12. Excessive
vibration in the
process of shock
absorber diagnostics.
Poor fixing of shock absorber in
pneumatic clamp.
Check fixing: lock nuts of
pneumatic clamps should be
safely tightened.
One of the two bearings in
upper/lower pneumatic clamp is
faulty.
Check bearing inner and outer
races for integrity. Replace
bearing in case of
deformation.
13. Test bench is out
of operation.
No power supply.
Check 400V power supply.
Automatic cutout is off.
Check automatic cutout.
Test bench power supply unit
failure.
Contact sales representative.
14. No display
respond to
operator’s touch.
Touch screen is damaged.
Contact sales representative.
15. Test bench
operating system
load failure.
Test bench operating system
failure.
Contact sales represantative.

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8 EQUIPMENT DISPOSAL
European Directive 2202/96/EG [WEEE (Waste Electrical and electronic Equipment)] applies to the
Test Bench disposal.
Obsolete electronic equipment and electric appliances, including cables, fittings and batteries
should be wasted separately from domestic garbage.
Use existing collection and recycling systems for waste disposal.
Proper waste disposal saves environment and personal health.