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MGS M0028 User Manual

Test bench for diagnostics of alternators and starters
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2024.03.14
M0028
TEST BENCH FOR DIAGNOSTICS
OF ALTERNATORS AND STARTERS
USER MANUAL

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  • Page 1 2024.03.14 M0028 TEST BENCH FOR DIAGNOSTICS OF ALTERNATORS AND STARTERS USER MANUAL...

  • Page 3: Table Of Contents

    English User Manual CONTENT INTRODUCTION ..............................1. APPLICATION ..............................2. SPECIFICATIONS .............................. 3. EQUIPMENT SET .............................. 4. TEST BENCH DESCRIPTION ........................... 4.1. Test bench menu ........................... 5. APPROPRIATE USE ............................5.1. Safety guidelines ........................... 5.2. Preparing the bench for operation ....................

  • Page 4: Introduction

    The present user manual consists of the information on the application, supply slip, specifications, methods of evaluation technical condition of automotive alternators and starters, as well as the rules of safe operation of M0028 test bench. Read carefully this manual before putting M0028 (hereinafter “bench”) into operation.

  • Page 5: Specifications

    English User Manual 2. SPECIFICATIONS Supply voltage, V Supply mains type Three phase Drive power, kW Dimensions (L x W x H), mm 655×900×1430 Weight, kg Quantity of storage batteries 2 similar lead-acid by 12V (not included into supply slip) Battery capacity 45Ah min Storage battery automatic charging...

  • Page 6: Equipment Set

    English Test bench M0028 Starter diagnostics Power of diagnosed starters, kW up to 11 Additional features Software update Available Alternator database Available Diagnostics results storage Available Printing Available Internet connection Wi-Fi (802.11 a/b/g/ac), Ethernet Connection of peripheral devices 2 x USB 2.0 3.

  • Page 7: Test Bench Description

    English User Manual 4. TEST BENCH DESCRIPTION The bench consists of the following main elements (fig. 1): Figure 1. Overall view of the diagnostic bench 1 – Door for access to the battery compartment. 2 – Working platform. 3 – Protective cover. 4 –...
  • Page 8 English Test bench M0028 Work Platform (Fig. 2) includes the following elements: Figure 2. Work platform of the bench 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.
  • Page 9 English User Manual Figure 3. Control panel of the bench 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.
  • Page 10 English Test bench M0028 Figure 5. Universal diagnostic cable MS-33001 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.
  • Page 11 English User Manual • 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.
  • Page 12 English Test bench M0028 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. To diagnose 48 V alternators, the MS-33401 cable is used (Fig. 8).

  • Page 13: Test Bench Menu

    English User Manual Figure 9. Set of special cables for diagnosing alternators To diagnose the starter, it is necessary to use the MS-33001 cable and the cable for connecting to starter terminal 50 (see Fig. 10). Figure 10. Cable for connecting to starter terminal 50 4.1.
  • Page 14 English Test bench M0028 Figure 11. Main menu of the bench 7 – Battery status indicators. 8 – Indicator of open/closed protective cover. 9 – Indicator of closed bench doors. Diagnosis is not possible with any door open. 10 – Indicator of the "EMERGENCY STOP" button pressed.

  • Page 15: Appropriate Use

    English User Manual Figure 12 5. APPROPRIATE USE 1. Use the test bench as intended only (see Section 1). 2. The test bench is intended for indoor use at temperatures ranging from +10 to +40 °C and with relative humidity not exceeding 75% without condensation. 3.

  • Page 16: Safety Guidelines

    English Test bench M0028 8. In case of failures in the operation of the bench, stop further operation and contact the manufacturer or sales representative. WARNING! The manufacturer is not responsible for any damage or injury to human health resulting from non-compliance with the requirements of this user manual.

  • Page 17: Alternator Testing

    English User Manual Prior to the bench operation, connect: 1) Storage batteries 12V that have to be located in the storage battery section of the bench (fig.9). The left door is opened with the keys (included to the supply slip). While connecting the storage batteries refer to the power cable markings.

  • Page 18: Installation And De-Installation Of The Alternator

    English Test bench M0028 6.1. Installation and de-installation of the alternator 1. Use the "Release Chain" button to increase the length of the chain sufficient for securing the alternator. A single press increases the length of the chain, and a subsequent press stops this process.
  • Page 19 English User Manual 6. Screw the adapter onto the "B+" terminal (see Fig. 15). Figure 15 7. Connect the black power wire "B-" to the unit's housing and the red power wire "B+" to the adapter (see Fig. 16). Figure 16. Connection of Power Wires to the Alternator 8.

  • Page 20: Connecting The Diagnostic Cable To The Alternator Connector

    English Test bench M0028 WARNING! Disassembly of the alternator is allowed only after the drive has completely stopped, and the testing mode has been exited. 6.2. Connecting the diagnostic cable to the alternator connector To assess the operability of the alternator, it is necessary to select an appropriate special cable or correctly connect the universal cable to the terminals in the alternator socket.
  • Page 21 English User Manual Figure 18 In case the alternator is not in the database, it is necessary to find the terminal designation in the alternator socket on the internet. Then, by identifying the alternator type based on the socket terminals, using the information in Appendix 1, you can select a suitable special cable or connect the universal cable.
  • Page 22 English Test bench M0028 Table 2 – Connection of Bosch 0986049191 Alternator to the Bench Color of the Terminal in the Diagnostic cable wire diagnostic cable alternator socket wire Lamp gray orange As another example, let's consider connecting the universal cable to the Toyota 2706020230 alternator (Fig.
  • Page 23 English User Manual As a final example, let's consider connecting the universal cable to the Nissan 23100EN000 alternator (Fig. 21). Figure 21. Nissan 23100EN000 Alternator and Terminal Designations in the Socket Based on the socket terminals in Fig. 21, we determine the alternator type. In this case, terminal C and the association with Japanese vehicles define the alternator type as C JAPAN.

  • Page 24: Alternator Test Menu

    English Test bench M0028 6.3. Alternator test menu When the alternator diagnostic mode is activated, a menu for selecting the type of diagnosed alternator opens (see Figure 22), which includes: Figure 22. Menu for Selecting the Diagnosed Alternator Type 1 - Button to return to the main menu.
  • Page 25 English User Manual Any alternator test script can be modified by the user at their discretion (see Appendix 8 – Setting the value of the alternator pulley diameter. This parameter is set for diagnosing the alternator with rotation frequencies equal to those on the car. During the diagnostic mode of any type of alternator, the following information may be displayed on the screen (see Figure 23): Figure 23.
  • Page 26 English Test bench M0028 8 - Control of the alternator drive rotation frequency. 9 - Control of the alternator rotation direction. Usually, alternators rotate clockwise (viewed from the pulley side). 10 - Button to stop the diagnostic process. "K15 U V" – Ignition circuit voltage value (K15).
  • Page 27 English User Manual Figure 24. Menu of the COM type alternator check mode "Type" – displays the code of the voltage regulator type operating under the "LIN" protocol: A1, A2, A3, A4, B1, B2, B3, B4, C3, D1, D2, E1. "Excitation"...

  • Page 28: Manual Mode 12 V And 24 V Alternator Diagnostics

    English Test bench M0028 Figure 25. Menu of the IStars 12V type alternator check mode 6.4. Manual mode 12 V and 24 V alternator diagnostics 1. After fixing and connecting the alternator, go to the "Alternator" menu. 2. In the opened window, select: the nominal voltage of the diagnosed alternator, 12 or 24 V, the type of alternator, the maximum test current, the diameter of the pulley.
  • Page 29 English User Manual Figure 26 3.2. Using the alternator drive control buttons (see item 1 in Figure 26), set the speed of the alternator pulley rotation within the range of 100 to 150 rpm. WARNING! If the alternator pulley has a freewheel clutch, carefully select the direction of rotation.

  • Page 30: Automatic Mode Diagnostic Mode For 12 And 24 V Alternators

    English Test bench M0028 6. Evaluate the operation of the voltage regulator by: 6.1. Setting the drive speed within 1500-2000 rpm. 6.2*. Using the output voltage control buttons (see item 6 in Figure 23), smoothly adjust the alternator's output voltage within the range from minimum to maximum. The measured voltage should change proportionally.
  • Page 31 English User Manual 3. Next, select the script to be used during the automatic test: Advanced script or Quick script, then press the "Automatic test" button. 4. After clicking the "Automatic test" button, a preliminary alternator check window will appear, see Figure 26.

  • Page 32: Diagnostics Of 48 V Alternators

    English Test bench M0028 6. After completing all the test stages, the bench automatically generates a report and opens it. Reports are saved in the folder C:\UserFiles\Reports. If it is necessary to find a specific test result in the future, it is necessary to save the obtained report under your name (for example, order number, client name, and date) in another folder.

  • Page 33: Starter Diagnostics

    English User Manual The sequence of operations is as follows: 1. Fix the alternator on the bench, connect the power cables. Use cable MS-33401 for connection to the socket. 2. Go to the "Alternator" menu, and then enter the diagnostic mode for 48 V alternators. 3.
  • Page 34 English Test bench M0028 Figure 29. Starter Testing Mode Menu 6 - Test initiation buttons: "MANUAL" - initiates the test in manual mode, the test lasts as long as the button is pressed; "AUTO" - initiates the test in automatic mode, the test lasts for 2 seconds. After the test, a report is generated.

  • Page 35: Test Bench Maintenance

    English User Manual 4. Connect the universal diagnostic cable K30 and K45 wires to the corresponding terminals of the starter, see Figure 30. 5. In the main menu, select the starter testing mode, then choose the nominal voltage of 12 or 24 V.

  • Page 36: Test Bench Firmware Update

    English Test bench M0028 • inspection of bench operation environment (temperature, humidity etc.). 8.1. Test bench firmware update Being connected to the Internet, with every switching on, the test bench checks for software updates of diagnostics program, database and bench firmware. In case the bench finds the software update at company server, you’ll be offered to install the update or disregard it.

  • Page 37: Recycling

    English User Manual 2. The bench runs but the electric motor The bench wiring is damaged. doesn’t start. 3. When the bench runs The diagnosed unit is mounted Re-mount the unit for the the abnormal noises are wrong. (The driving belt is over diagnostics.

  • Page 38: Appendix 1 - Connection Of Terminals To Alternators

    English Test bench M0028 APPENDIX 1 Alternator connection terminals Diagnostic Type of Application Code alternator cable wire Battery (+) (Ignition) Ignition start input Alternator Sense Battery Voltage Terminal for measuring of Sense battery voltage Sense Battery (-) (Earth) Earth, battery (-)
  • Page 39 English User Manual Diagnostic Type of Application Code alternator cable wire (Signal) Voltage code setting input (Digital) Input for voltage code setting on the American Ford, similar to SIG (Regulator Control) Similar to SIG (Regulated Voltage Control) Similar to SIG, with L(RVC) just the voltage variation range 11.0-15.5V.
  • Page 40 English Test bench M0028 Diagnostic Type of Application Code alternator cable wire Output of one of the alternator stator winding coils It’s used for the identification of the alternator excitation level by the voltage regulator Stator (Wave) Output of one of the alternator stator...

  • Page 41: Appendix 2 - Manual For Creating Scripts For Automatic Testing Of Alternators

    English User Manual APPENDIX 2 Manual for creating scripts for automatic testing of alternators CONTENT INTRODUCTION ..............................42 1. Writing a script ............................43 1.1. Data Types .............................. 43 1.2. Conditional Statement ........................44 1.3. Loop................................45 1.4. Wait Operator ............................46 1.5.

  • Page 42: Introduction

    English Test bench M0028 INTRODUCTION Automatic testing of alternators on the stand is carried out using scripts. You can use existing "Default script" or create your own "User script". Figure 2.1. Automatic generator test settings menu To make the program use custom scripts, you need to write them, name them accordingly (for example, if the generator type is Lamp 12 volts, then the script file name should be LAMP12.txt),...

  • Page 43: Writing A Script

    English User Manual Next, in the automatic generator test settings menu, you need to set the appropriate "User script" checkbox opposite the generator type for which the user script is written. ATTENTION! If scripts are accidentally deleted, new template files will be created when the software is launched.

  • Page 44: Conditional Statement

    English Test bench M0028 Another example: operation". Here, we declare a string value named #sOutputText="Starting OutputText and assign the value "Starting operation" as text. With numeric types, you can also perform standard mathematical operations (addition, subtraction, multiplication, division). For example: #fNormalCurrent=10 #fCurrent=13.7...

  • Page 45: Loop

    #iMaxLoad=150 End If In this case, we check if the value of the variable equals the text "M0028". If it does, #sTesterName the variable is assigned a new value of 300. If not, it is assigned a new value of 150.

  • Page 46: Wait Operator

    English Test bench M0028 1.4. Wait operator This operator can be useful when you need to check a condition over a certain period of time. It has the following structure: Wait(condition, time_in_milliseconds) It checks the condition every 100 milliseconds. If the condition is true, it continues down the script.
  • Page 47 English User Manual – sets the load in amperes. It accepts one argument as a number ranging from 0 to SetLoad() 300. – returns from the test stand as a floating-point number ranging from 0 to GetBPlusU() BPlusU 65535. – returns from the test stand as a floating-point number ranging from GetBPlusIDC() BPlusIDC...

  • Page 48: Limitations

    English Test bench M0028 1.6. Limitations To ensure the proper functioning of scripts, there are several limitations. For a better understanding of these limitations, you can visit the "Manual Test" section and review the data requirements. Number of Revolutions: When setting the number of revolutions, it's important to understand that the test stand can rotate from 0 to 3000 revolutions per minute.
  • Page 49 English User Manual When generating the report, these placeholders will be automatically replaced with the values generated during the test. This way, you can include any variables created during the test in your report. Since the report is created in Excel, you can use its full functionality when creating a template: formulas, rules, formatting, etc.
  • Page 50 Produced by STS SP.Z.O.O ul. Modlińska, 209, Warszawa 03-120, Poland +48 833 131 970 E-mail: sales@servicems.eu Website: msgequipment.pl Technical Support msgsupport@servicems.eu +380 67 434 42 94 (WhatsApp, Viber, Telegram)

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