MSG Equipment MS1000+ User manual

USER MANUAL
MSG MS1000+
TEST BENCH FOR DIAGNOSTICS OF SHOCK
ABSORBERS MSG MS1000+
2017.05.17
QUALITY UNIQUENESS
INNOVATION TRAININGSERVICE
WARRANTY

User Manual - Test bench MSG MS1000+
2
INTRODUCTION..........................................................................................................................................................3
1. SAFETY MEASURES.............................................................................................................................................3
2. DESCRIPTION AND OPERATION.......................................................................................................................5
2.1 Test bench description and operation ...............................................................................................6
2.1.1 Technical characteristics................................................................................................................6
2.1.2 Packing and equipment set..........................................................................................................7
2.1.3 Installation location.......................................................................................................................7
2.1.4 Test bench construction and operation...................................................................................7
2.2 Test bench component parts description and operation.............................................................8
2.2.1 General information and working chamber operation ......................................................8
2.2.2 Pneumatic clamp adjustment.....................................................................................................9
2.2.3 Lower pneumatic clamp height adjustment..........................................................................10
2.2.4 Puller stroke adjustment .............................................................................................................11
2.2.5 Shock absorber nitrogen filling block......................................................................................12
2.2.6 Control panel...................................................................................................................................12
2.2.7 Pneumatic clamp pedal control unit........................................................................................13
3. PROPER USE.........................................................................................................................................................13
3.1 Operating restrictions..............................................................................................................................13
3.2 Test bench preparation for use.............................................................................................................13
3.3 Test bench use............................................................................................................................................14
4. TEST BENCH MAINTENANCE.............................................................................................................................19
4.1 Invertor maintenance...............................................................................................................................19
4.2 Gear motor maintenance ........................................................................................................................20
4.3 Air-preparation unit maintenance .......................................................................................................23
5. TEST BENCH RUNNING REPAIR........................................................................................................................24
6. STORAGE...............................................................................................................................................................25
7. TRANSPORTATION...............................................................................................................................................27
8. TEST BENCH WASTE............................................................................................................................................27
9. TEST CERTIFICATE ..............................................................................................................................................27
CONTENTS

User Manual - Test bench MSG MS1000+
3
INTRODUCTION
We are grateful for choosing MSG Equipment. Test bench for diagnostics of shock absorbers MSG
MS1000+ (hereinafter, MS1000+) is made of high quality components and materials consisting of the
latest diagnostic equipment manufacturing technologies.
MS1000+ distinctive features:
• diagnostics of shock absorbers of different construction types;
• testing of shock absorbers under load with different speed and simulation of car in motion;
• opportunity to compare testing results;
• diagram creation over existed one;
• saving and printing of testing results;
• user-friendly software.
Actual User Manual is an essential component of the test bench. It contains information on appli-
cation, compound parts, functioning and construction of MS1000+, its technical characteristics and
all necessary details regarding exploitation. The manufacturer reserves the right to change compo-
nent parts and software without preliminary notice of users.
It is strongly recommended to learn actual User Manual MS1000+ before launching the equipment,
take special training at the manufacturing enterprise if necessary. Safety requirements should be
strictly observed. Special attention should be paid to text with notes ‘DANGER’, ‘WARNING’ in actual
User Manual. Non-observance of ‘WARNING’ instructions may cause serious consequences under
certain conditions. It is necessary to follow the instructions of all sections for personnel safety.
The following indications will be used in actual User Manual:
Symbol Meaning Description, recommendations, notes
WARNING Dangerous situation implying slight injury or material
damage could occur
DANGER Dangerous situation implying serious injury or damage
of the test bench could occur
1. SAFETY MEASURES
DANGER

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User Manual - Test bench MSG MS1000+
1. It is strictly forbidden to launch the test bench while gear motor unit doors are open. There is a
risk to touch exposed conductive parts of electric potential up to 380V and get electric shock.
2. It is strictly forbidden to conduct any connections to terminals of electric motor and invertor;
open protective elements; disassemble the frame under connected supply voltage and 10 minutes
after disconnection of the test bench (live capacitors save dangerous voltage in current-carrying
part for some time after supply disconnection).
3. It is strongly recommended to avoid disassembling, modifying or repairing the test bench per-
sonally. It may cause electric shock, fire accident or other damage. Issues on repair should be di-
rected to the Supplier.
4. It is strictly forbidden to connect output terminals U/T1, V/T2, W/T3 to power supply as far as it
will cause total destruction of invertor, fire accident or other damage, and removal of warranty li-
ability by the Supplier. It is essential to check connections to avoid possible danger.
5. The test bench should be effectively grounded.
6. Disconnect supply of the test bench with ‘OFF/ON’ switch when it is out of use.
7. Shock absorber should not be disassembled while it is fixed in diagnostics unit. It may cause
deformation of pneumatic clamp.
8. Disconnect supply of the test bench before starting any maintenance works. There is a risk of
electric shock.
9. It is strongly recommended to avoid leaving the test bench in mode of diagnostics unattended.
WARNING
1. Disconnect power supply from the test bench in case of any failure. Long lasting current flow may
lead to deflagration or damage of electric motor winding.
2. MS1000+ should be used in well-ventilated premises only. Existence of vapor containing highly
flammable matters in the air may cause fire accident.
3. The test bench should be used in accordance with the instructions described in actual User
Manual.
4. It is strongly recommended to check insulation state in supply electric cable regularly.
5. Mounting and dismounting of shock absorber should be conducted carefully to prevent its fall
or deformation.
6. Use filters to reduce electromagnetic interference degree. Otherwise, nearby electronic devices
may be adversely affected by it.
7. If the test bench is out of service for a long time, it is strongly recommended to inspect and check
it before launching.
8. Use of inappropriate computer facilities or programs will cause removal of warranty liability

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User Manual - Test bench MSG MS1000+
(even if computer facilities or programs were shortly after removed or deleted).
9. The test bench should not be altered, except the manufacturer. Use of the equipment is avail-
able along with its original component parts and accessories only. Non-observance of this point
will cause removal of warranty liability. Only original software is available for use on actual test
bench. Besides, MSG Company is not responsible for any damage caused by installing inappropriate
programs.
2. DESCRIPTION AND OPERATION
2.1 T    
Test Bench MS1000+ is a specialized equipment item, manufactured for service centers specializing
in repair and maintenance of shock absorbers for motor cars and trucks. Diagnostics of mono-tube
and twin-tube gas charged shock absorbers with diverse combinations of upper and lower mount-
ing. (Fig. 1).
Fig. 1 – Shock absorbers with different types of working part fittings
Diagnostics of shock absorber is conducted through dynamogram record (data on how applied
force depends on shock absorber shaft position). Maximum load available is 1000 kg.
Specialized pneumatic vice is used for quick, safe and easy fixing of shock absorbers of any type.
The clamp controlled by PC, control panel or pedal unit.
Available shock absorber testing modes: manual and automatic. Available speed options in manual
mode: 60, 120, 180 rpm. Available speed options in automatic mode: up to 6 free speed options.
Testing results can be saved in a file and be set as a template for further diagnostic circles.
The test bench is connection to the Internet through Wi-Fi. Software update and technical support
is available through Internet connection.
Nitrogen filling block for shock absorber can be optionally included in the delivery set.
Do not test shock absorbers with spring, it may cause damage of the test bench.

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User Manual - Test bench MSG MS1000+
Name Value
Voltage, V 380±10%
Power supply, kW 3.7
Supply type Three-phase (3L+N+PE)
Dimensions W×D×H, mm 2460×1042×482
Weight, kg 350
Clamp control Pneumatic
Test bench pneumatic system power pressure, bar 6
Requirements to pressed air of test bench pneumatic
system
Cleaned air, no need in air-oil lubricator.
Setting of 25 m centrifugal filter pro-
viding air purity class on the standard
ISO 8573-1:2010 [7:8:4] is required
Shock absorber testing
Shock absorber shaft stroke Adjustable
Shock absorber shaftstroke adjustment Manual
Shock absorber shaftstroke adjustment range, mm 0-140
Height adjustment of shock absorber fixing Manual
Bound/rebound maximum load, kg 1000
Operation mode Manual/automatic
Quantity of testing modes 1-6
Testing modes (by default)
Speed 1 – 30 rotations
Speed 2 – 60 rotations
Speed 3 – 90 rotations
Speed 4 – 120 rotations
Speed 5 – 150 rotations
Speed 6 – 180 rotations
Output parameters
–Bound/rebound
–Shock absorber temperature
–Shock absorber stroke
Print output data Yes
Connection to the Internet Wi-Fi (802.11 a/b/g/ac)
2.1.1 T 

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User Manual - Test bench MSG MS1000+
2.1.2 P   
The test bench is delivered safely packed in a strong box for equipment transportation. It is essen-
tial to inspect the test bench and check it for damage after its unpacking. Packing materials are to
be wasted totally: place it in the corresponding places for separate waste collection.
The manufacturer is not responsible for material damage, injury of people or animals occurred in
consequence of non-observance of the instructions described.
The equipment set includes:
– Test Bench MS1000+;
– Set of changeable fittings for shock absorber – 3 pairs;
– Handle for fixing pneumatic clamp lock nuts – 1 piece;
– Universal prism for fixing shock absorbers with rod end – 2 pcs +1 piece with uncalibrated holes
(for shock absorber with irregular shafts);
– Pneumatic clamp pedal control unit (optionally);
– Shock absorber nitrogen filling block (optionally);
– User Manual for Test Bench MS1000+.
2.1.3 I 
The test bench does not require mounting to the foundation due to its construction and has inclina-
tion up to ±0,1%.
2.1.4 T    
Fig. 2 – Test Bench MS1000+ (front view)

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1– working unit; 2– mechanical unit; 3– shock absorber nitrogen filling block; 4– display;
5– control panel; 6– electrical unit; 7– pneumatic clamp pedal control unit.
User Manual - Test bench MSG MS1000+
Initial connection of the test bench implies application of the following fittings and connectors:
- electric line – socket 3P+PE+N 16A, 380, IP-44 stationary IEK;
- pneumatic line – quick disconnect coupling 5180 G1/4 (Camozzi);
- nitrogen filling block – quick disconnect coupling 5480 8/6 (Camozzi).
The manufacturer is not responsible for incorrect indication of measuring
due to application of inappropriate connectors.
2.2 T      
2.2.1 G     
Fig. 3 – Working chamber
1– pneumatic upper clamp; 2– pneumatic lower clamp (Fig. 4); 3– lower clamp lock with fixation;
4– rotation wheel; 5– puller threaded part lock; 6– temperature sensor.
Delivered optionally.
Delivered optionally.

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User Manual - Test bench MSG MS1000+
Upper and lower pneumatic clamps (1, 2) arepneumatic cylinders, used for fixation of tested shock
absorber.
Lower clamp lock with fixation (3) is used for fixing of lower clamps with regard to puller rotation
wheel.
Shaft threaded part lock (5) is used for lift lockout of lower clamp mechanism along
pullerthreaded joint.
Fig. 4 – Pneumatic lower clamp
1, 4– pullers; 2, 3 – shock absorber changeable fittings.
Fig. 5 – Shock absorber changeable fittings
Adjustment is conducted in order to synchronize stroke of pullers of pneumatic clamps.
Adjustment is carried out with throttles (Fig. 6) through changing of speed of pneumatic cylinder
air filling.
2.2.2 P  

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User Manual - Test bench MSG MS1000+
Fig. 6 – Position of adjusting throttleson pneumatic clamps (bottom view on upper clamps)
Take the following steps to adjust height of lower pneumatic clamps:
–Unblock threaded lock (1) by 90 degrees turn (Fig. 7).
–Unblock lower pneumatic clamp lock (2).
–While turning rotation wheel (3), set a needed height of pneumatic clamps.
–On finishing adjustment of height of lower pneumatic clamps, block threaded lock and clamp
lock.
2.2.3 L    
Fig. 7 – Strokecontrol of lower pneumatic clamps
1 – air exhaust throttle; 2 – air supply throttle to pneumatic cylinder.
1 –threaded lock; 2 – lower pneumatic clamp lock; 3 –rotation wheel.

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User Manual - Test bench MSG MS1000+
Puller stroke adjustment mechanism is used for setting operating stroke (motion range) of puller
depending on tested shock absorber type.
Position sensor is used for indication of puller stroke and location at the moment.
2.2.4 P  
Fig. 8 – Puller stroke adjustment unit
1 – bearing; 2 – puller stroke adjustment mechanism; 3 – puller; 4 – position sensor; 5 – puller
shaft mechanism fixing screws.

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User Manual - Test bench MSG MS1000+
2.2.5 S    
Fig. 9 – Shock absorber filling block
1 – cylinder nitrogen pressure indicator; 2 – line pressure indicator; 3 – nitrogen cylinder; 4 – gear;
5– filling coupling nitrogen pressure control; 6– filling coupling.
Fig. 10 – Control panel
1 – 'OFF/ON' switch; 2 –'EMERGENCY' button; 3 – pneumatic clamp control buttons.
2.2.6 C 
'OFF/ON' switch (1) is used for test bench activation/deactivation.
'EMERGENCY' button (2) is used for test bench emergency stop.
Pneumatic clamp control buttons (3) are used for regulation of upper and lower pneumatic clamps.

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User Manual - Test bench MSG MS1000+
2.2.7 P    
Fig. 11 – Pneumatic clamp pedal control unit
Pneumatic clamp pedal control unit is used as a backup mechanism of pneumatic clamp control.
This feature gives an opportunity to mount tested unit with both hands.
3. PROPER USE
3.1 O 
It is strongly recommended to use computer and other active network connections, included in the
equipment set, in indoor heated premises under stable climatic environment. Computer, invertor
and active network connections operate at temperatures from +1° to +30°, under atmosphere
relative humidity - from 10 to 90% at temperature +30° (without water condensation).
Computer and other active network connections, included in the equipment set, withstand short
(3-5 sec.) static vertical load on the frame up to 0,25 kg/cmunder total load on the frame up to 80
kg, except interface and power connectors.
Test Bench MS1000+ is resistant to electrostatic discharge, network voltage dynamic changes, high-
energy microsecond impulse interference in power supply circuit.
3.2 T    
Remove shipping foam packing.
Do not take the test bench in the place of opening parts and perforation on relocating it.
Install the test bench on solid and flat floor surface. Make sure that all four legs stand firmly on
the floor and the test bench is installed strictly vertically (use leveling gauge). The surface should
withstand pressure up to 2500 Pa spread on the area of 1,5 m.

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User Manual - Test bench MSG MS1000+
Connect the test bench to pressed air system. Power pressure 6-10 bar.
Inspect the test bench for existence of damage. If it is found, contact either the manufacturer or
trade representative before launching the equipment.
In case of obvious damage, use of equipment is forbidden.
3.3 T  
1. Install a specialized tool - prism adapter on tested shock absorber if necessary. Fix shock ab-
sorber upper fitting in upper clamps and press ‘Close upper clamp’ on the display ( ),
or control panel (Fig. 12).
Open pneumatic clamps only when doors are open and motor is stopped.
Testing of shock absorber is forbidden when working unit door is open.
Fig. 12 – Upper clamp closing
2. Adjust height with lower clamps adjustment system (Fig. 7). In this regard, unblock threaded
lock (1) and lower clamp lock (2), set the needed height with Rotation wheel (3). Fix shock absorber
lower fitting with ‘Close lower clamp’ button on the display
( ) or with control panel (Fig. 13).
Always fix shock absorber safely. Poorly fixed shock absorber will show incorrect re-
sults and may damage the equipment.

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User Manual - Test bench MSG MS1000+
Fig. 13 – Lower clamp closing
3. Use rotation wheel to bring shock absorber into functional area and block locks (Fig. 14). Press
the button ‘Test turnover’ on the display to make sure that shock absorber is mounted within its
operating stroke. The motor will make 2 turns at minimum speed.
Operator’s hand should be placed on emergency button to stop the motor immediately
in case of irregular operation during test turnover.
Fig. 14 – Shock absorber functional area adjustment
4. When test turnover passes successfully, calibrate force sensor in zero value (Fig. 15).

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User Manual - Test bench MSG MS1000+
Fig. 15 – Force sensor zero calibration (sensor value is highlighted)
2 testing modes are active after zero calibration: manual and automatic (Fig. 16).
Fix temperature sensor (if necessary) to shock absorber with zip tie before testing.
Fig. 16 – Testing mode selection
3 speeds are available in manual testing: 60, 120 and 180 rpm. Corresponding graphs will be
recorded after motor reaches the needed speed. Free velocity can be set with the buttons «+» and
«-». Free velocity graph will be displayed as ‘Manual’.
Corresponding force values will be displayed on ‘Bound’ and ‘Rebound’ indicators (Fig. 17).

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User Manual - Test bench MSG MS1000+
Fig. 17 – Shock absorber manual testing mode
Set testing program before shock absorber automatic testing. Press the button ‘Settings’ in the
main menu (Fig. 18), where speed and rotation is set for every testing procedure (in upper left side
of the screen). Quantity of testing modes: from 1 to 6.
In settings menu preferable measuring units, operator and company name, language can be set,
hardware part operation can be checked as well.
Fig. 18 – Settings window

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User Manual - Test bench MSG MS1000+
Automatic testing (Fig. 19) has the opportunity to compare testing results with the previous ones. In
this regard, press the button ‘Open’ and select previously saved data. Results will be loaded in the
table and graphs. Testing settings also change (speed and quantity of testing modes). Previously
received graphs become inactive after pressing the button ‘Start’, previous results will be displayed
in the table in brackets, new values will be displayed without brackets.
Fig. 19 – Automatic testing
Use corresponding buttons to save and print the results.
There is an opportunity to compare testing results any time. Press 'Testing results’ in the main
menu. There are 2 fields in the appeared window (Fig. 20) where testing results of different shock
absorbers are downloaded. Results can be all together and separately printed.
Fig. 20 – Testing results window

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User Manual - Test bench MSG MS1000+
Shock absorber is dismounted from the test bench in reverse order when testing is finished.
4. TEST BENCH MAINTENANCE
Test Bench 1000+ is intended for long lasting operation under twenty-four-hour schedule. However,
it is essential to inspect the test bench and observe preventive measures described below with
recommended intervals for trouble-free enduring operation. Inspection and preventive measures
should be carried out by a qualified specialist.
Danger of injury due to immediate test bench launch.
• Switch off and disconnect the test bench, block it to prevent its unintended use!
Special attention should be paid to the following aspects of daily inspection:
– appropriate operation of the motor (no unusual sounds, excessive heat, vibration, etc.);
– appropriate environmental conditions for test bench use (temperature, humidity, air contamina-
tion, vibration, etc.);
– appropriate voltage range (voltage meter measuring).
It is recommended to clean test bench frame with soft tissue or cloth using neutral cleaners after
finishing daily operating shift. The monitor should be cleaned with microfiber cloth.
It is recommended to tighten force sensor lock nut at least once per 3 months.
It is recommended to oil sliding joints of puller shaft and pneumatic clamps with lithium grease
‘LITOL - 24’ at least once per 6 months.
4.1 I 
VFD-E up-to-date digital invertor is intended for long lasting operation under twenty-four-hour
schedule.
It is essential to inspect the test bench and observe preventive measures (at least once per 6
months) described below with recommended intervals for trouble-free enduring operation.
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, excessive heat,
vibration, etc.);
– appropriate environmental conditions for test bench use (temperature, hu-
midity, air contamination, vibration, etc.);
– appropriate cooling system operation;
– appropriate test bench operation (no unusual noise and vibration);
– appropriate voltage range (voltage meter measuring).
Invertor daily
inspection

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User Manual - Test bench MSG MS1000+
Constant current link capacitors save high voltage for some time after supply
disconnection. Proceed to invertor inspection 10 minutes after LED POWER
on printed board is off. Use tester to make sure that residual voltage between
‘+’ and ‘-‘ terminals is less than 25 V.
Invertor
inspection
frequency
1. Invertor maintenance is available for qualified specialists only.
2. Works connected with opening of protective covers and disconnection of conductors
should be conducted when power supply is off!
3. Remove all metal objects (watch, rings, etc.) before proceeding to work.
Use insulated tool.
4. It is strictly forbidden to disassemble test bench internal components and
disconnect internal connections.
General list of recommended inspections to conduct at least once per 6 months:
1. Check wire fastening of power terminal blocks and remote control bar.
2. Check wires, cables, their insulation for damage. Cable insulation local color change indicates
on fault.
3. Conduct visual inspection of invertor and make sure that there is no foreign objects inside.
4. Clean radiator, power elements, construction components, control panel, connector and other
parts from dirt and dust by vacuuming or air blowing under pressure 4-6 kg/cm.
5. Remember that dirt and dust may reduce invertor term of service or cause its failure.
6. Check heating conditions of invertor and motor. Pay special attention to operation of fan
(rotational freedom, noise, heating, contamination).
7. Switch on invertor (operation without motor activation is acceptable), reform its electrolytic
capacitor and confirm its functional capabilities at least once a year.
Note: Non-observance of above described instructions may cause invertor premature failure.
4.2 G  
Frequency Preventive measures
Every 3000 hours of operation, at least once per 6
months.
• oil level and quality check;
• bearing condition check (noise in the process of
operation);
• visual inspection of sealing tightness.
Depends on operation conditions, at least once per 3
years.
• change of mineral oil*;
• lubrication change in antifriction bearings (recom-
mended);
• change of cups (distributing edge displacement from
shaft worn out side).
Diverse (depends on external environment). Recovery or refreshing of lacquer and corrosion-resis-
tant coating.
* mineral oil CLP220 in total of 0,70 l is recommended for use as the main one.