2650-1876-77 5/10/17
®
Auto Meter Products Inc.
413 West Elm St Sycamore, IL 60178
Service (815) 899-0801
Toll Free (866) 883 TEST (8378)
www.autometer.com/test
-How to Use the Tester-
-Full System Alternator Test-
4
Inspect the belt and cables.
Check off each task when
completed by pressing the
check buttons. Press OK
when finished.
This screen will appear showing
how to connect the tester. Connect
the large Red clamp to the positive
(+) terminal of the alternator. The
large black clamp to the alternator
ground. Connect the small Red
clamp to the (positive) + terminal of
the starting Battery Pack and the
small Black clamp to the negative
(-) terminal of the starting Battery
Pack.
Enter the rated output current of the
alternator by pressing the button
with the rated current displayed. A
keypad will appear. Press START
TEST when ready to continue.
If loads are required
the unit will prompt
you to turn the
headlights and fans
on before proceeding.
When this screen
appears rev the
engine to governor
speed
The BCT-460 will
complete the test.
The results of the Alternator cable’s
voltage drop test will be displayed.
If the cables passed, press the
PROCEED TO NEXT TEST button
to continue the Alternator test. If the
cables fail the BCT-460 will instruct
you to repair the cables. If on the
second pass the cables still fail you
will have the option to accept the
cables “AS IS”.
Press the START button to begin
the Alternator Test
The BCT-460 will
prompt you to start
the engine.
Set the engine idle
at about 1000 RPM
and wait for the
voltage to stabilize.
Press the Press
When Stable button
to continue.
1. Good Alternator: The alternator passed all its tests.
2. Bad Regulation: The alternator output voltage was either too
high or to low.
3. Bad Diodes: The tester detected that the diodes in the
alternator have failed.
4. Low Output: The alternator is not putting out enough
current.
5. Bad Cables: The tester detected a high voltage drop on
the alternator cables.
For instructions on how to do the PM Test or Individual Tests. See the
Owners Manuals.
Alternator Test Results
BCT-460 Hand-Held Battery & System Analyzer
®
Control and Load Module Mated and Latched Load Module
Control
Module
Latch
Charging
Port
Load Module Push Button
Power on: Push and hold button for 1 second
Power off: Push and hold for more than 5 seconds
Reboot/Reset: Push and hold button for 3 to 4 seconds
Units may be totally discharged when received. Use the
wall charger to fully charge unit before use.
Control Module Push Button
Power on: Push red button for 3 seconds.
Power off: Push red button for 2 seconds.
Note: Control module must be removed from
load module to power down.
CONTROLS AND FUNCTIONS
Control Module
USB Type A
Status LED
USB Type B
Control Module
Latch
Charging Port
Factory Use Only
Voltage drop lead
connectors
Temperature Sensor
BCT-460 I/O Items
USB Type A - This port is used to connect USB memory sticks to save test
data to, and for Control module application updates and Load module firmware
updates. The Control module must be docked to the Load module to use this
feature. Charger must not be in charging station to use USB port.
USB Type B - Factory use only.
Temperature Sensor: The Load module has an IR temperature sensor that is
used to measure the temperature of the battery you are testing.
Charging Port: When the unit is not being used it should be connected to the
charger.
Status LED Load Module Mode
Off Off
Solid Yellow Initial boot-up or test in progress
Fast Blinking Green Re-Flashing/Firmware Updated
Solid Green Bluetooth Disconnected
Blinking Green (Double Flash) Bluetooth Connected
Blinking Green ( Slow, once/sec) Sleeping/Low Power
Solid Red Internal Battery Charging
Blinking Red (Slow, once/sec) Control Module Battery Charging
Blinking Red (Fast, twice/sec) Initializing Bluetooth
Set Date/Time & Time Zone
Time Zone
• From Main Menu press SETTINGS.
• Scroll down and press Set Date and Time
• From Date & Time menu press Select Time Zone
• From resulting list choose your local time zone
Date and Time
• If the tester will have a WiFi connection to the internet leave
Automatic date & time selected (check mark)
• If there will be no internet connection press Automatic date & time
to deselect option and continue to set the local date and time.
Date
• Press Set date and enter today’s date in the resulting setting box.
Time
• Press Set time and enter the local time in the resulting setting box.
• Press the Back Arrow twice to return to the main menu.
Setup Wifi
• From Main Menu press SETTINGS.
• Scroll down and press WiFi Setup
• Select your local WiFi from resulting list
• Enter password for your local WiFi in resulting setting box
• Once password has been entered press Connect
• Press the Back Arrow twice to return to the main menu
WARNING!
TESTING OF HYBRID VEHICLES
DO NOT test the starter, alternator and/or 12 volt starting battery while it is in the vehicle.
DO NOT remove, service or test the hybrid battery pack under any circumstances.
Remove the 12 volt starting battery, starter or alternator from the vehicle prior to testing.
-Full System Test Battery Test-
-Battery Pack Test Results-
1. Good Battery Pack: The Battery Pack is of sufficient state of charge.
2. Low State of Charge: The Battery Pack is at a low state of charge. Charge Battery Pack. The Battery Pack must be higher
than 75% state of charge to provide accurate electrical system test results.
3. Bad Positive Battery Pack interconnect VDrop: Voltage drop on the positive Battery Pack interconnect exceeds specification.
•Reference shop manual for repair procedure.
4. Bad Negative Battery Pack interconnect VDrop: Voltage drop on the negative Battery Pack interconnect exceeds specification.
•Reference shop manual for repair procedure.
5. Bad interconnect VDrop: The sum of both positive and negative interconnect VDrops exceed specification.
•Reference shop manual for repair procedure.
2
Follow the proper safety
procedures when working
around batteries.
Select Full System Test to
start.
If you are starting a new test on a
Vehicle press the New button. If you
are resuming a test press Resume.
If the vehicle has an Auxiliary Battery Pack press
Yes. The tester will then instruct you to disconnect
the Auxiliary Battery Pack from the Starting Bank.
Follow the on screen instructions. Check
all issues that the customer is reporting.
Press Next to proceed. Press Previous to
go back to the first screen.
Enter the vehicles VIN and odometer
reading. Enter any relevant comments.
Press OK to continue or Previous to go
back one page.
Reassemble battery pack and connect the tester
to the Battery Pack as shown. Place the large
red clamp on the positive (+) terminal on one of
the batteries on the edge of the bank. Place the
large black clamp on the negative (-) terminal on
the opposite end of the bank. Connect the small
red clip to the positive terminal on the opposite
side of the bank as the large red clamp. Connect
the small black clip to the positive terminal on the
opposite side of the bank as the large black clamp
The following screen will appear.
You will be required to enter the
values for the battery rating, type,
and temperature. These can be
changed by pressing the button on
the right for the value you want to
change. Press Start Battery Test
when all entries are correct and you
are ready to test the Battery Pack.
When the Measure Battery Temp
area is pressed, the temperature
probe screen is activated. Aim the
temperature probe on the bottom of
the load module at the battery from
a distance of less than 6 inches.
Press Save to store temperature
reading and go back to the Battery
Pack Test screen.
Enter how many batteries were
replaced in the Battery Pack. This
screen will appear twice. Once for
the Starter Bank and once for the
Auxiliary Bank (if the vehicle has one).
You will now be instructed to complete
the final test of the Battery Pack.
After the final test is completed
the results of the Battery Pack test
will be displayed. Please refer to
the owners manual for detailed
descriptions of possible results and
what next instructions.
Follow on screen instructions to test the batteries
individually, See owners manual for more details.
-How to Use the Tester-
-Full System Test Starter Test-
3
Inspect the Starter cables
and press the check
button when finished.
Press START TEST when ready
to continue.
Disconnect the control module from
the load module. Make sure the engine
is off. Connect the large leads of the
load module to the starter. Connect the
small leads to the battery. Place the
load module in a stable location in the
engine compartment. Take the control
module with you to the cab. Make
sure all accessories are off. Press the
CONTINUE button.
The results of the starter cable’s
voltage drop test will be displayed.
If the cables passed, press the
PROCEED TO NEXT TEST button
to continue to the Starter test. If the
cables fail the BCT-460 will instruct
you to repair the cables. If on the
2nd pass the cables still fail you
will have the option to accept the
cables “As Is”
The BCT-460 will display “Does the
Vehicle Crank?” If it does, press the
YES button and the BCT-460 will
proceed to the starter test. If the
vehicle does not crank press the NO
button and the BCT-460 will proceed
to the IMS circuit test. This test is
described in detail in the owners
manual.
Press the START button to
begin the test.
Once the Starter test begins the BCT-460 will do
some preliminary measurements. This takes about 7
seconds.
When the BCT-460 is ready it will prompt you to
turn the key to the run position. Once the ECU has
powered up and initialized and grid heater/glow plugs
turn off, start the engine. Once you engage the
starter, the BCT-460 will finish the test.
If engine compression strokes are detected the
BCT-460 will ask how many cylinders the engine
has so it can calculate the cranking RPM.
The results of the starter test will be displayed.
Refer to the owners manual for a description of the
possible results and whats nest descriptions. Press
the PROCEED TO NEXT TEST button to continue to
alternator test.
1. Good Starter: The starter passed the test.
2. Bad Starter: The starter failed the test due to one of the following
reasons. Starting RPM was not high enough. The
circuit is bad.
3. Bad Start Enable Circuit: Trouble shoot faulty start enable circuit.
4. Abutment: An abutment is when the gears of the starter motor
and the flywheel gear do not mesh properly. If it
happens once then repeat the starter test. If it
happens more than once replace the starter.
5. Fail Low RPM: The starter failed due to low cranking RPM.
cables was too high.
Starter Test Results
/
