Auto Meter Remy BCT-200J Instruction Manual
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Auto Meter Remy BCT-200J Instruction Manual

Battery load, charging system, starting system and voltage drop tester for truck maintenance optional j1708 hookup
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60
T est Equipment
®
With PM TEST
AGM Compatible
U.S. Patent No.
6,061,638
6,359,442
D442,503
6,771,073
VDROP is a
trademark of
Auto Meter Products
BCT-200J
Instruction Manual
Battery Load, Charging System, Starting System and
Voltage Drop Tester for Truck Maintenance
Optional J1708 Hookup
Complement your battery testing with complete system test including a
voltage drop test that measures the voltage drop of the starting and
charging circuit. The BCT-200J is automated and menu driven with
simple hook-up methods for testing the negative and positive legs in one
operation. Special tests are included for the magnetic switch circuit.
1

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Summary of Contents for Auto Meter Remy BCT-200J

  • Page 1 6,061,638 6,359,442 D442,503 6,771,073 VDROP is a trademark of Auto Meter Products BCT-200J Instruction Manual Battery Load, Charging System, Starting System and Voltage Drop Tester for Truck Maintenance Optional J1708 Hookup Complement your battery testing with complete system test including a voltage drop test that measures the voltage drop of the starting and charging circuit.

  • Page 2: Specifications

    CONGRATULATIONS! NOTES You have purchased one of Auto Meter's hand-held Voltage Drop Analyzers. It is designed to test each circuit of a trucks starting and charging circuit with speed and accuracy. If you should have any questions about your tester or the testing procedures please see back cover for contact information.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS T est Equipment Specifications --------------------------------------------------------------- 2 Safety ------------------------------------------------------------------------- 4 Cause of Battery Failure ------------------------------------------------- 4 Inspection and Visual Check -------------------------------------------- 5 Controls and Functions --------------------------------------------------- 6 Test Sections PM Test --------------------------------------------------------7 Battery Bank Test ---------------------------------------- 8-9 Individual Battery Test -------------------------------10-12 Charging Cable VDrop Test ------------------------13-15 * Single * Dual...

  • Page 4: T Est Equipment

    SAFETY LIMITED WARRANTY 1 YEAR FROM DATE OF PURCHASE CABLES 90 DAYS n Carefully read all operating instructions The manufacturer warrants to the consumer that this product will be free from defects in before operating the BCT-200J material or workmanship for a period of one (1) year from the date of original purchase n Wear eye protection when working on (90 Days for cables).

  • Page 5: Inspection And Visual Check

    The software will be available from a CD or can be downloaded from our website. before proceeding with any test on the charging or starting Contact Auto Meter for more information. system. n I nspect Belts for cracks, glazed surface and fraying. Tighten loose belts.

  • Page 6: Controls And Functions

    Note: For other software applications consult your software manual. KEYS: n Make sure menu is displayed as shown in illustration page 20 step 3. When each key is pressed, AUTO METER/REMY n Select “Capture Text” in the Transfer Menu. a beep sounds to assure INTELLI-CHECK2J n Type in c:\my documents\download.txt and then select “Start.”...

  • Page 7: Pm Test

    DOWNLOAD TEST INFORMATION PM TEST PC Screen Menu The PM Test should only be used n If the BCT-200J is properly connected to your PC and the LCD during a time when the vehicle shows “ ” the menu should CONNECT ANALYZER TO A PC is in the shop for a PM Service, NOT when the vehicle is having automatically be displayed in Hyper Terminal.

  • Page 8: Battery Bank Test

    BATTERY BANK TEST USING WINDOWS 98/2000/NT/XP Note: The BCT-200J will interface with any basic (ANSI) terminal emulation software. Most operating systems contain a program that NOTE: When performing a PM Test the tester will automatically run the Battery will do this. Following are instructions for Windows. For other operating Bank Test to make sure that the battery bank passes.
  • Page 9 Consider where the vehicle Using Auto Meter’s AC-35 Application Program has been before adjusting. By purchasing Auto Meter’s PC Application Program, information >ENTER BATT TYPE that is stored and collected in the BCT 200J can be easily AGM USE +/- Use the (+) or (-) key to select the downloaded into a PC program format for storage.

  • Page 10: Individual Battery Test

    INDIVIDUAL BATTERY TEST SETUP (Cont.) To require a battery serial number before >REQUIRE BATTERY each battery test select YES. If YES is SERIAL #? NO selected then before each battery test When the test results appear as USE +/-. the tester will prompt for a 14 digit alpha- #211 12V BANK GOOD BATTERIES after running 'Y' TO SELECT.
  • Page 11 SETUP INDIVIDUAL BATTERY TEST (Cont.) Post Adapters Make sure post REVIEW/PRINT adapters are From the main menu select VOLT METER screwed firmly SETUP. J1708 DATA against the lead >SETUP pad. >SET TEMPERATURE Select the temperature in SCALE: F. Fahrenheit or Centigrade. The prompt only appears if the user USE +/-.
  • Page 12 FIVE TEST RESULTS VOLT METER Select VOLT METER from the GOOD BATTERY ALTERNATOR main menu and press (Y Enter). The battery has passed the load and capacity tests STARTER TEST This gives the user a chance to REVIEW PRINT and is at a high enough state of charge to continue check the voltage from the large >VOLT METER clamps and the external leads.

  • Page 13: Charging Cable Vdrop Test

    15 ft. of the printer. Wait for the screen to clear before moving the BCT- 200J. It takes a moment to send all the test data. The BCT-200J also operates ALTERNATOR the AC-14 printer installed in Auto Meter’s XTC-160 tester/charger or BVA-2100 HOOKUP heavy duty tester/analyzer.
  • Page 14 REVIEW TESTS CHARGING CABLE VDROP™ (Cont.) From the main menu select REVIEW/PRINT The Charging System Test performs this individual VDrop LOADING Test before allowing you to test PLEASE WAIT... the alternator’s output. VDROP MENU The last test will be displayed. If all connections are correct press ALTERNATOR (Y Enter) to begin VDrop Test.
  • Page 15 CHARGING CABLE VDROP™ (Cont.) MAINTENENCE VDROP ERROR MESSAGES CLAMP INSPECTION One of the following may appear during any drop test sequence. Correct IMPORTANT: Both jaws of each CHECK OFTEN FOR LOOSE JAWS the situation before continuing. clamp must firmly engage all OR DAMAGED INTERNAL PLASTIC terminals.

  • Page 16: Alternator Output Test

    STANDARD ALTERNATOR OUTPUT TEST ALTERNATOR BENCH TESTING (Cont.) #48 12V BENCH BAD After the battery or batteries have been tested and were good (or have been replaced) and after the charging cables have been tested and ALTERNATOR HIGH RIPPLE were good (or were repaired or replaced) you may proceed to test the REG.
  • Page 17 ALTERNATOR BENCH TESTING (Cont.) STANDARD ALTERNATOR OUTPUT TEST (Cont.) See photo of non remote sense DOES ALTERNATOR alternator alternator below “N” for ALLOWING VOLTAGE Non-remote sense alternator HAVE A TO STABILIZE REMOTE SENSE? 14.47V. 'N' OR 'Y' PLEASE WAIT . . . Non Remote Sense Alternator TESTING ALTERNATOR...
  • Page 18 STANDARD ALTERNATOR TEST RESULTS ALTERNATOR BENCH TESTING (Cont.) FLIP BATTERY SWITCH TO >CONNECT R CLIP ALTERNATOR. TO THE R TERM 'N' TO CANCEL. ON ALTERNATOR 'Y' TO CONTINUE The BCT 200J will check the bench CHECKING BENCH battery to ensure that it is charged and BATTERY sufficiently good to continue with the alternator test.
  • Page 19 ALTERNATOR BENCH TESTING (Cont.) STANDARD ALTERNATOR TEST RESULTS If the prompts are skipped over by ALTERNATOR AND pressing the +/Up key then a prompt is TESTING ALT. displayed indicating that the alternator TESTER SHOULD BE Wait for test to complete its and the tester should at this point be PLEASE WAIT...
  • Page 20 ALTERNATOR BENCH TESTING (Cont.) REMOTE SENSE ALTERNATOR OUTPUT TEST After the battery or batteries have been tested and were good (or have been replaced) and after the charging cables have been tested and Align the belt so that it is straight and MAKE SURE THAT will not come off.

  • Page 21: Remote Sense

    ALTERNATOR BENCH TESTING REMOTE SENSE ALTERNATOR TEST (Cont.) See photo of remote sense DOES ALTERNATOR The Bench Test is used to test the alternator that has been removed alternator. HAVE A REMOTE SENSE? from the vehicle and setup on an alternator test bench. Select 'Y' for remote sense From the main menu select Bench 'N' OR 'Y'...

  • Page 22: Battery Test

    DEFINITIONS - SYSTEM SPECIFICATIONS REMOTE SENSE ALTERNATOR TEST (Cont.) BATTERY TEST Attach the cable from the tester to During each battery test the BCT-200J uses various results that are >ATTACH J-1708 the data port on the vehicle. displayed after each test. The definition of those results are as follows: DATA CABLE •...
  • Page 23 REMOTE SENSE ALTERNATOR TEST (Cont.) LIFTGATE VDROP™ TESTS (Cont.) Generic System >REV ENGINE TO Setup GOV. FOR 10 S. Rev the engine to governed speed for 10 seconds. If no results appear press (Y Enter). 'N' TO CANCEL TESTING ALT. Wait for test to complete its testing PLEASE WAIT...

  • Page 24: Main Starting Cable Vdrop Test

    (end of the “stinger” cord). Adapters are available from Auto Meter to facilitate connecting the BCT-200J to single pole and dual pole connectors on both trucks and trailers. See the manual supplement that is included with those adapters for more detailed information on testing and trouble shooting the liftgate charging circuits and liftgate motor circuits.
  • Page 25 KEY SWITCH VDROP™ TEST (Cont.) (NON OCP) STARTING VDROP™ MAIN CABLE. . . SINGLE NON OCP Starter Positive Black Starter Ground >CONNECT LARGE LEADS TO THE Connect large leads to the STARTER Starter 'Y' TO CONTINUE Then connect small leads to the >CONNECT SMALL battery bank –...
  • Page 26 STARTING MAIN CABLE VDROP™ (Cont.) SINGLE KEY SWITCH VDROP™ TEST (Cont.) (OCP) #10 MAIN CABLES #11 MAIN CABLES PASSED @ 500A OUT OF SPEC @ 500A GOOD TO 375A GOOD TO 545A 0.18 POS 0.13 NEG 0.21POS 0.36NEG. STARTING VDROP™ . . . SPLIT SYSTEM TESTING PART A CHARGING CABLES BATTERY TEST...
  • Page 27 KEY SWITCH VDROP™ TEST (Cont.) SPLIT SYSTEM TESTING (Cont.) PART A Scroll to 250 amps. ENTER RATED Should read voltage at ext. V. No -VOLTMETER- CURRENT: 250 voltage at magnetic switch coil with VOLTS 0.00V ignition key off. EXT. V 12.63V 'Y' TO CONTINUE 0.00 POS 0.00 NEG...
  • Page 28 SPLIT SYSTEM TESTING (Cont.) PART B KEY SWITCH VDROP™ TEST Now test the other battery pack. Note: This is a real time test and the operator must observe and record BATTERY TEST the data when the key switch is energized. BATTERY BANK >VDROP MENU ALTERNATOR...
  • Page 29 SPLIT SYSTEM TESTING (Cont.) PART B MAGNETIC CIRCUIT TEST (Cont.) ENTER RATED If the test was out of spec Press #338 MAG/CIRCUIT 'Y' and the BCT-200J will advance CURRENT: 250 Scroll to 250 amps. OUT OF SPEC! to the next menu. Excessive drop DROP @ 80A: 1.54V at rated load is indicated by more 'Y' TO CONTINUE...

  • Page 30: Magnetic Circuit Vdrop Test

    MAGNETIC CIRCUIT VDROP™ TEST MAGNETIC CIRCUIT TEST (Cont.) DISCONNECT THE This is the small wire on the starter The Magnetic switch circuit supplies a path for current to the coils of the starter S-TERMINAL FROM solenoid that activates the starter solenoid with minimum voltage drop.

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