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+
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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+
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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.