MSG MS005 User manual

2022.07.28
MS005
MANUAL ON DIAGNOSTICS
OF ALTERNATORS AND STARTERS
INSTRUKCJA DIAGNOSTYKI
ALTERNATORÓW I ROZRUSZNIKÓW
ИНСТРУКЦИЯ ПО ДИАГНОСТИКЕ
ГЕНЕРАТОРОВ ИСТАРТЕРОВ
UNIQUENESS
TRAINING
SERVICE
NNOVATION
WARRANTY
QUALITY

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CONTENTS
INTRODUCTION....................................................................................................................................................4
1. TEST BENCH DESCRIPTION............................................................................................................................5
2. TEST BENCH MENU........................................................................................................................................10
3. APPROPRIATE USE........................................................................................................................................12
3.1. Safety Guidelines...................................................................................................................................12
4. ALTERNATOR DIAGNOSTICS .......................................................................................................................13
4.1. Connection of the wires of diagnostic cable to alternator connector terminals.................13
4.2. Alternator diagnostics menu .............................................................................................................16
4.3. Alternator diagnostics in manual mode..........................................................................................19
4.4. Alternator diagnostics in automatic mode.....................................................................................21
5. STARTER DIAGNOSTICS ...............................................................................................................................23
5.1. Starter diagnostics menu ...................................................................................................................23
5.2. Starter diagnostics............................................................................................................................... 24
APPENDIX 1.........................................................................................................................................................25
CONTACTS.......................................................................................................................................................... 28
APPENDIX 2 ........................................................................................................................................................81

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INTRODUCTION
The present manual contains the description of the methods of evaluation of technical condition
of automotive alternators, starters and voltage regulators at the bench MS005 (hereinafter “the
bench”).
WARNING! MSG Equipment is not responsible for any harm caused by the improper usage of
equipment.
Test bench MS005 checks:
1. The technical condition of automotive alternating current alternators with rated voltage 12 and
24V under the load up to 150 and 75 A accordingly, including alternators of system
«start-stop» 12V.
The diagnostics of automotive alternators and voltage regulators takes into account the following
criteria:
- Stabilizing voltage;
- control lamp working performance capacity;
- FR (displaying of the frequency and FR duty ratio, voltage regulator response).
- The AC pulsation value.
For COM alternator types (voltage regulators):
- ID;
- Protocol;
- data exchange speed;
- LIN protocol type;
- regulator self-diagnostics errors.
2. Automotive starters with power of 11kW with rated voltage 12 and 24 V, without load (at idle).
The diagnostics of the automotive starters considers the voltage changes nature and the currents
on the terminals 30, 45 and 50.
3. 12V automotive lead-acid storage batteries by residual capacity.

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1. TEST BENCH DESCRIPTION
The bench consists of the following main elements (fig. 1):
Figure 1. Overall view of test bench
1– Access door to storage battery location.
2– Working spot.
3– Protective housing.
4– Touch screen - to display diagnostic parameters of a diagnosed unit and to control the bench
functions.
5– Control panel.
6– Pivot wheels with brake.

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The working spot (fig.2) consists of the following components:
Figure 2. Bench working spot
1– Alternator drive belts: V-belts and poly V-belts.
2– Power cables «В+» «В-».
3– Unit fixing chain.
4– The bracket for a diagnostic cable alligator clips.
5– Thermal vision camera.
6– Diagnostic cable connection port.
7– Diagnostic cable connection port for starter diagnostics.
The control panel (fig.3) consists of:
Figure 3. Bench control panel
1– buttons to control the tightening and loosening of alternator drive belt.

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2– buttons to control the tightening and loosening of unit fixing chain.
3– button «COVER» - opens the protective housing.
4– button «OFF/ON» - is responsible for the power on the bench. The bench is turned off by
pressing the button «Turn off the bench» in the main menu of the service program.
5– Button «EMERGENCY STOP» - emergency stop of generator drive and chain/belt tightening.
In the bottom of the touch screen there are two USB ports (fig.4 ref. 1) for connecting the computer
periphery (mouse, keyboard, WiFi adapter) and network LAN port (ref. 2).
Figure 4. Position of USB and LAN ports
The bench supply slip includes the diagnostic cable (fig.5) that consists of the adapting wire kit
(fig.6) - for more convenient connection to alternator connection terminals.
Figure 5. Diagnostic cable MS-33001

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Figure 6. Adapting wire kit
The diagnostic cable MS-33001 has the following adapting wire color codes (see also Table 1):
•Orange - S(Sense Pin) - the terminal that enables the measuring of the storage battery voltage
by the voltage regulator as well as it compares the storage battery voltage with the alternator
output voltage. This adapting cable is connected to terminal S;
•Red – IG (Ignition) – the terminal is used for the connection of the ignition circuit, the
terminals: 15, A, IG;
•White – «FR» – the terminal that transmits the data on the regulator load. This adapting wire
is connected to the following terminals: «FR», «DFM», «M»;
•Gray – «D+» – the terminal for the connection of the circuit of voltage regulator control lamp.
It’s connected to the terminals: «D+», «L», «IL», «61»;
•Yellow – «GC» – is used for the connection of the channel of alternator voltage regulator
control. This adapting wire is connected to the following terminals: «COM», «SIG», etc.
•Brown – «К30» – is connected to the starter terminal 30 that is connected to the storage
battery terminal «+».
•Violet – «К45» – is connected to the starter solenoid output connected with starter electric
motor.

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Table 1 – Color codes of cable MS-33001
Connector
Terminal
S
IG
FR
Lamp
GC
K30 (starter)
K45 (starter)
For convenient usage of the diagnostic cable, it’s recommended to put the alligator clips onto the
bracket (ref. 4, fig.2).
Figure 7. Diagnostic cable alligator clips that are set on the bracket.

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For the diagnostics of the starter, use the cable MS-33001 and the cable for the connection of the
terminal 50 (fig.8).
Figure 8. Cable for the connection of starter terminal 50
2. TEST BENCH MENU
The bench main menu (fig. 9) consists of:
Figure 9. Bench main menu
1 – Bench OFF button.
2 – Button to enter alternator database.
3 –Alternator diagnostics activation button.
4 – Starter diagnostics activation button.
5 –Information on the condition of the batteries connected to the bench.