Auto Meter BCT-460 Operator's Manual
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Auto Meter BCT-460 Operator's Manual

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BCT-460
Operator's Manual
Hand Held-Accuracy with a Pulsed 120 Amp Load Heavy Duty
The BCT-460 is the ultimate hand-held tester. It is the industry's answer to
portability in a professionally accurate load tester and system analyzer.
1

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Summary of Contents for Auto Meter BCT-460

  • Page 1 � BCT-460 Operator's Manual Hand Held-Accuracy with a Pulsed 120 Amp Load Heavy Duty The BCT-460 is the ultimate hand-held tester. It is the industry's answer to portability in a professionally accurate load tester and system analyzer.
  • Page 2 The BCT-460 is a portable full-featured menu-driven battery tester, starting, and charging system analyzer that provides quick, professional load results using Auto Meter's Digital Pulse Load. The BCT-460 is user friendly. It guides you through the test and tells you what to do next.

  • Page 3: Table Of Contents

    Using the Optional Current Probe ............36 Trouble Shooting ................. 37 Warranty ....................38 Note: The BCT-460 performs a complete electrical system test that checks the battery bank, starter cable voltage drop, starter test, alternator cable voltage drop, and alternator test.

  • Page 4: Specifications

    20 degrees. Allow the battery to warm to room temperature before testing or charging. Warning! Never attach the BCT-460 to a battery that is connected to any other tester or charging unit. Damage may result. CAUSE OF BATTERY FAILURE Incorrect Application: Wrong size battery may have inadequate cold cranking rating for original vehicle specifications.

  • Page 5: Inspection And Visual Check

    INSPECTION Valid heavy duty electrical system testing depends on all the components being in good operating condition. In addition, the battery MUST have sufficient charge for testing. Carefully perform the following steps before attempting any electrical diagnosis. VISUAL CHECK Inspect Belts for cracks, glazed surface and fraying. Tighten loose belts. Inspect Battery for terminal corrosion, loose or broken posts, cracks in the case, loose hold-downs, low electrolyte level,...

  • Page 6: Wireless Communication

    WIRELESS COMMUNICATION BLUETOOTH The BCT-460 uses Bluetooth to communicate between the control module and load module. This allows you to make the connections, remove the control module and the run the tests from inside your vehicle. The BCT-460 control module and load module come paired from the factory.
  • Page 7 BCT-460 I/O Items USB Type A - This port is used to connect USB memory Temperature Sensor: The Load module has an sticks to save test data to, and for Control module IR temperature sensor that is used to measure the application updates and Load module firmware updates.
  • Page 8 The About screen give The Test Results user the information screen shows a list of about the applications the test that have been version and how to done and allows the contact Auto Meter. user to view all the details of the test.

  • Page 9: Set Up

    SET UP OPTION MENU DETAILS Allows pairing to Bluetooth Devices. Update Control Module and Load Module software. Check Battery Status. Show list of Test Results. Adjust Control Module volume. Quick Main Menu help. Starts Demo Mode (if demo mode files are present) About the Tester.

  • Page 10: Tester Configuration

    TESTER CONFIGURATION Store Information For use with AMPNET. Set if email is desired for test result. Default Email: Email will be sent to the account associated with AMPNET Subscription. Customer Email: Allows the customer to provide a new email address to receive results.

  • Page 11: Saving Data To Usb Flash Drive

    SAVING DATA to a USB FLASH DRIVE 1. Control Module must be docked to Load Module. 2. Tester must be disconnected from all charging sources. 3. Plug USB flash drive into connector on the right side of tester. 4. Wait a few seconds for the USB flash drive to be detected.

  • Page 12: Hook Up

    HOOK UP Connect Black Clamp to Connect Red Clamp to Negative (-) Terminal Positive (+) Terminal CONNECTION ERRORS If the clamps are reversed the Reversed Connection warning will be displayed on the Control Module with an audible beeping. If one or both of the clamps are not in complete contact (both of each clamp jaws) A "Check Connections"...

  • Page 13: Pm Test

    Enter the It will ask you to number of rev the engine batteries in the to the governor bank speed. Enter the The BCT-460 will Keep the individual now do some engine revving battery measurements at governor information, to prepare for the...
  • Page 14 PM TEST The BCT-460 will prompt you to return the engine speed to idle speed and then complete the alternator test. The BCT-460 will now display the results of the PM Test.
  • Page 15 FULL SYSTEM (BATTERY BANK TEST) Main Menu screen. Click on the Full System Test Button to start. These two screens allow user to check off customers complaints. The buttons on these screens allow the user to move back and forth The user will between them.
  • Page 16 FULL SYSTEM (BATTERY BANK TEST) This unit will Disassemble Reassemble ask if the battery pack and the battery vehicle has an test batteries pack auxiliary battery individually bank. If does then the This unit will Note how unit will instruct show the user many the user to...
  • Page 17 FULL SYSTEM (BATTERY BANK TEST) The user will The user can enter be asked the rating of a how many single battery in batteries are the bank. He can in the bank. also choose the type of rating the battery has. The user can enter the type of battery in...

  • Page 18: Battery Bank Test

    If the starter passed but an alternator repair was needed, then the unit will proceed to the alternator test. NOTE: The BCT-460 will do the starter bank test first and then the auxiliary bank.

  • Page 19: Starter Cable Voltage Drop Test

    The small black clamp goes to the Battery Bank negative (-). The BCT-460 will The BCT-460 will display make sure the the results. If the voltage engine is off, if it drop is good the user will be isn’t the following...
  • Page 20 FULL SYSTEM (STARTER CABLE VOLTAGE DROP TEST) If the voltage drop is high , the user will be instructed to repair the cable on the first pass. On the 2nd or later tries the user is given the option to Accept “As Is”...

  • Page 21: Starter Test

    The BCT-460 will use the logged data to determine the cranking current, cranking voltage, cranking time, and cranking Turn the key to If the engine the run position.

  • Page 22: Alternator Voltage Drop Test

    FULL SYSTEM (ALTERNATOR VOLTAGE DROP TEST) The BCT-460 will instruct If the voltage drop is high, the user to visually check the user will be instructed the belt and alternator to repair the cable on the cables and connections. first pass.

  • Page 23: Alternator Test

    FULL SYSTEM (ALTERNATOR TEST) The BCT-460 will need The BCT-460 will make some to know if the alternator preliminary is a Remy or other, then measurements press start to continue. to prepare for the alternator test. Start the Engine If the BCT-460 determines...
  • Page 24 FULL SYSTEM (ALTERNATOR TEST) The results of The BCT-460 will the test will be instruct the user to displayed. Any rev the engine to failure will be governor speed and highlighted in red. hold it there. While the engine is...

  • Page 25: Individual Tests

    Select battery test. be selected. Press the battery type you are testing and the unit will go back to the Battery Test screen. The battery types the BCT-460 can test are Starting Standard and Starting AGM. When the Select Battery Rating...
  • Page 26 INDIVIDUAL TESTS (BATTERY TEST) These screens show the results the BCT-460 will return after a battery test. The information shown is test number, measured capacity, rated capacity, the state of health and the battery’s initial voltage. All tests are saved internally in the BCT-460.
  • Page 27 INDIVIDUAL TESTS (BATTERY TEST) The battery did not have sufficient remaining capacity to pass the test. The battery should be replaced immediately. The battery did not have sufficient remaining capacity to pass the loaded portion of the test. The battery should be replaced immediately The battery did not have a sufficient charge to do...

  • Page 28: Starter Test

    Turn the key to If the engine starting the run position. RPM was detected, Wait for the ECU the BCT-460 will ask to power up. how many cylinders the engine has to determine the starting RPM. If not then the...
  • Page 29 INDIVIDUAL TESTS (STARTER TEST) No Crank Situation The BCT-460 will The test will show the user determine how to connect whether the large red clamp problem to starter positive. is with the Connect large starter. black clamp to starter ground.

  • Page 30: Alternator Test

    INDIVIDUAL TEST (ALTERNATOR TEST) The BCT-460 The BCT-460 will need will make some to know if the alternator preliminary is a Remy or other, then measurements press start to continue. to prepare for the alternator test. Start the Engine If the BCT-460 determines...
  • Page 31 INDIVIDUAL TEST (ALTERNATOR TEST) The BCT-460 will instruct the user to rev the engine to governor speed and hold it there. The results of the test will be displayed. Any failure will be highlighted in red. While the engine is...

  • Page 32: Starter Cable Test

    VOLTAGE DROP TEST (Starter Cable Test) The voltage drop test allows you to measure the voltage drop across both the positive and negative cables running from the battery to the starter and alternator or any other device within your vehicle. This test can be used to determine if the cables or connections are the cause of any problems.

  • Page 33: Charging Cable Test

    VOLTAGE DROP TEST (Charging Cable Test) Select individual tests, then To set the test select the V DROP Test from current, press the Test current box the main menu. and a numeric keypad will appear. Enter in the alternator output for the vehicle you are testing.

  • Page 34: Generic Cable Test

    VOLTAGE DROP TEST (Generic Cable Test) Select individual tests, then To set the test current, press the select the V DROP Test from Test current box and a numeric the main menu. keypad will appear. Enter in the test current for the circuit you are testing.

  • Page 35: Voltage Drop Test Results

    If a total system voltage drop the positive and negative circuit greater than 500mV is is less than 500mV, the voltage measured, the BCT-460 drop test passes. If the voltage will show a failed voltage drop test. drop test fails you should start by...

  • Page 36: Using The Optional Current Probe

    USING THE OPTIONAL CURRENT PROBE The Current Probe is optional. This section explains the proper use of the Current Probe, but is not required to run any of the tests. It only provides assured accuracy for those wanting these results. When the probes is not connected push and turn to Zero the current probe.

  • Page 37: Troubleshooting

    Clean any corrosion from the battery post and the clamps. connected them. • If the battery is completely dead, (Voltage less than 1 volt.) the BCT-460 will not detect the battery. Charge the battery before testing. I have tested a battery and got a •...

  • Page 38: Warranty

    LIMITED WARRANTY 12 MONTHS FROM DATE OF PURCHASE The manufacturer warrants to the consumer that this product will be free from defects in material or workmanship for a period of twelve (12) months from the date of original purchase. (90 days for cables and clamps.
  • Page 39 Auto Meter Products Inc. � �� � � ��� �� ��� 350 West Center Street Pleasant Grove, Utah 84062 Auto Meter Products Inc. Service (801) 785-0051 ext. 223 413 West Elm Street Toll Free (866) 883-TEST (8378) Sycamore, IL 60178 Fax (801)785-8699 www.autometertest.com...

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