AutoMeter BCT-460 User 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.

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CONGRATULATIONS!
BCT-460
Load Test Capacity...............................................120 Amp
Battery sizes.........................................................100-1600 CCA
Display ................................................................7" (1024X600) LED, Wide Viewing Angle
Volt Ranges..........................................................Digital 0-30
Cooling.................................................................Vented
Leads ...................................................................Load Amp-4 ft., 6 Gauge
Size ......................................................................19" X 9" X 3"
Internal Battery.....................................................7.4 Volt Lithium Ion
Weight ..................................................................7 lbs.
What to Expect from the BCT-460:
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.
Caution: The BCT-460 grill may get hot after repeated use. Be sure to hold the unit from
the side grips only. Keep hands away from the grill. Keep oil and liquids away from the grill
and load coils.
You have purchased one of Auto Meter's hand-held Electrical System Analyzers. It is designed
to test each component of a truck’s electrical charging and starting system with speed and
accuracy. If you should have any questions about your tester, testing procedures, or service
see the last page of this booklet for contact information.

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TABLE OF CONTENTS
Specications ...................................................................................... 2
Safety ................................................................................................. 4
Inspection and Visual Check ............................................................... 5
Wireless Communication..................................................................... 6
Controls and Functions........................................................................ 6-8
Set Up ................................................................................................. 9
Tester Conguration ............................................................................ 10
Saving Data to USB Flash Drive ......................................................... 11
Hook Up............................................................................................... 12
PM Test................................................................................................ 13-14
Full System Tests
Battery Bank Test ..................................................................... 15-18
Starter Cable Voltage Drop Test............................................... 19-20
Starter Test ............................................................................... 21
Alternator Voltage Drop Test .................................................... 22
Alternator Test .......................................................................... 23-24
Individual Tests
Battery Test .............................................................................. 25-27
Starter Test ............................................................................... 28-29
Alternator Test .......................................................................... 30-31
Voltage Drop Tests
Starter Cable Test..................................................................... 32
Charging Cable Test ................................................................. 33
Generic Cable Test ................................................................... 34
Voltage Drop Test Results ................................................................... 35
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.

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Carefully read all operating instructions
before using the BCT-460
Wear eye protection when working
around batteries.
Be sure each test is completed before
removing load clamps to prevent arcing
and potential explosion from battery
gases. Never remove load clamps
while testing. Keep sparks ames, or
cigarettes away from batteries.
Keep hair, hands, and clothing as well
as tester leads and cords away from
moving blades and belts.
Provide adequate ventilation to remove vehicle exhaust.
In extremely cold temperatures, check for frozen electrolytic uid
before applying load. Do not attempt to Load Test or charge a battery
under 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.
Incorrect Application: Wrong size battery may have inadequate cold cranking rating for
original vehicle specications.
Incorrect Installation: Loose battery hold-downs cause excessive vibration, which can
result in damage to the plates.
Improper Maintenance: Low electrolytic uid and corrosion on battery connections can
greatly reduce battery life and affect battery performance.
Age of Battery: If the date code on the battery indicates it is fairly old, the failure may be
due to natural causes.
Overcharging: Overcharging caused by a high voltage regulator setting or incorrect
battery charging can cause excessive gasing, heat and water loss.
Undercharging: Undercharging caused by a faulty charging system or low voltage
regulation can cause lead sulfate to gradually build up and crystallize on the plates greatly
reducing the battery's capacity and ability to be recharged.
SAFETY
CAUSE OF BATTERY FAILURE

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Valid heavy duty electrical system testing depends on all the components being in good operating condition. In addition,
the battery MUST have sufcient charge for testing. Carefully perform the following steps before attempting any electrical
diagnosis.
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,
moisture, and dirt around the terminals.
If the battery terminals are corroded or
dirty, clean terminals before performing any
tests.
Inspect Starting System. Check starter, solenoid, and regulator for loose connections,
loose mounts and frayed or cracked wires.
Important Note: A damaged battery must be replaced before proceeding.
INSPECTION
VISUAL CHECK

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CONTROLS AND FUNCTIONS
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.
Bluetooth will work as long as the distance between the load module and control module is less than 30 feet. Walls, windows and
other objects between the control module and load module will affect the range.
If you do experience any communication issues please look at the troubleshooting guide at the back of this manual on how to
correct them.
Wi-Fi
The BCT-460 uses WiFi to communicate between the control module and AMPNET server. The AMPNET service will provide
rmware updates for the control module and the load module. You will need to pair the control module with your local wireless
LAN. See Wi-Fi section for instructions on setting up the wireless connection.
AMPNET
The data from your BCT-460 can be downloaded to the data management software known as AMPNET (purchased separately).
This software that can be used to display and track your battery, starting system, and charging system test results in graphical
form.
WIRELESS COMMUNICATION
Control and Load Module
Mated and Latched
Control Module Load Module
Control
Module
Latch
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

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CONTROLS AND FUNCTIONS cont.
USB Type A
Status LED USB Type B
Control Module
Latch
Screw to
replace leads
Charging and Amp Clamp Port
Voltage drop lead
connectors
Temperature Sensor
BCT-460 I/O Items
Main Menu: When the
Control Module powers
up it will go to the main
menu. From here the user
can access all of the units
functions such as, run tests,
setup the unit, and review
past test data.
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.
NOTE: The Load Module must not be connected to a
battery or the battery charger to use the Type
A 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 placed on the charger (or optional charging station) to
keep the batteries fully charged.
LED Status 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

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The About screen give
user the information
about the applications
version and how to
contact Auto Meter.
The Test Results
screen shows a list of
the test that have been
done and allows the
user to view all the
details of the test.
Update software screen
allows the user to
update both the Control
modules application or
the Load module firmware.
Battery Status screen
shows the state of
charge of the batteries
in the Control module
and the Load module.
CONTROLS AND FUNCTIONS cont.

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SET UP
SET DATE/TIME & TIME ZONE
OPTION MENU DETAILS
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 Wi-Fi 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 Wi-Fi
• From Main Menu press SETTINGS.
• Scroll down and press Wi-Fi Setup
• Select your local Wi-Fi from resulting list
• Enter password for your local Wi-Fi in resulting setting box
• Once password has been entered press Connect
• Press the Back Arrow twice to return to the main menu
1. Allows pairing to Bluetooth Devices.
2. Update Control Module and Load Module software.
3. Check Battery Status.
4. Show list of Test Results.
5. Adjust Control Module volume.
6. Quick Main Menu help.
7. Starts Demo Mode (if demo mode files are present)
8. About the Tester.
9. Opens Owner’s Manual Viewer
10. Force upload of complete system tests.
11. Opens Tester Configuration Screen.
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TESTER CONFIGURATION
1. Store Information
2. 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.
3. Additional test data. Check to enable
additional test data for individual tests.
4. Temperature °F of °C.
5. Set to default to use previously used battery
rating unit. Clear to use previous rating value.
6. Set to default to use previously used rating
value. Clear to use default rating value.
7. Set to show a Near End of Life result. Clear to
show only Good and Bad battery result.
8. “Default CCA” Value.
9. Set will calculate cranking RPM starter result.
Clear skips calculation.
10. Use to select default alternator setting in
alternator test.
11. Choose language for tester.
12. Wi-Fi Setup.
13. Date and Time Setup.
14. Select print device.
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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 ash drive into connector on the right side of tester.
4. Wait a few seconds for the USB ash drive to be
detected. The following screen will be displayed.
5. Choose SAVE DATA and press OK.
6. Choose data format and press SAVE.
7. Wait a few seconds and remove USB ash drive.

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HOOK UP
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" screen will appear on the control module.
Clean battery terminals with a wire brush if battery terminals are corroded or dirty.
Clean clamp jaws with 1 part ammonia and 10 parts water if clamp jaws are corroded or
dirty.
Connect Black Clamp to
Negative (-) Terminal Connect Red Clamp to
Positive (+) Terminal
BATTERY
Clean Clamps Corroded Clamps

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PM TEST
The PM test should only be used during a time when the vehicle is in the shop for a PM service, NOT when the vehicle is
having electrical system issues. For a vehicle with a suspected electrical problem use the Full System Test.
Select PM test
from the main
menu.
Enter the
number of
batteries in the
bank
Enter the
individual
battery
information,
and then press
Start Battery
test to test the
battery bank.
The BCT-460
will ask you
to start the
engine.
It will ask you to
rev the engine
to the governor
speed.
Keep the
engine revving
at governor
speed for about
10 seconds
while the BCT-
460 tests the
alternator
The BCT-460
will now test
the battery
bank.
The BCT-460 will
now do some
measurements
to prepare for the
starter test.

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PM TEST
The BCT-460
will now display
the results of
the PM Test.
The BCT-460
will prompt you
to return the
engine speed to
idle speed and
then complete
the alternator
test.

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Main Menu screen. Click on
the Full System Test Button
to start.
The user will
be asked if the
is a new test or
does he want
to resume a
previous test.
If Resume is
chosen a list
of active tests
will appear and
the user can
choose the test
he wants to
resume
Safety Screen
These two screens allow
user to check off customers
complaints. The buttons
on these screens allow the
user to move back and forth
between them.
FULL SYSTEM (BATTERY BANK TEST)
The user can enter
the VIN, odometer
reading, and any
comments. If entering
VIN a full valid VIN is
required.
Next Page

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This unit will
ask if the
vehicle has an
auxiliary battery
bank.
Disassemble
battery pack and
test batteries
individually
Reassemble
the battery
pack
Note how
many
batteries
replaced
If does then the
unit will instruct
the user to
disconnect the
auxiliary bank
from the starter
bank.
This unit will
show the user
how to connect
up to the battery
bank.
This unit will
ask how many
batteries are in
pack.
Continue with
individual battery
test as referenced
in individual test
(battery test)
section of this
manual. Continue
testing batteries
for all batteries in
pack.
FULL SYSTEM (BATTERY BANK TEST)

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The user will
be asked
how many
batteries are
in the bank.
On this screen
the user will
enter the
information
needed to run
the test.
The user can
enter the type
of battery in
the bank.
The unit will
continuously read
the temperature
from the IR
temperature
sensor and display
it.
The entered
information is now
displayed on the
screen.
The user can enter
the rating of a
single battery in
the bank. He can
also choose the
type of rating the
battery has.
Next Page
FULL SYSTEM (BATTERY BANK TEST)

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The BCT-460 will now do
the nal test of the starter
bank. it will then ask you
to repeat the test on the
auxiliary bank if the vehicle
has one. If this is the nal
test of either the starter
bank or auxiliary bank,
the unit will show the test
results.
This screen shows
the results of the nal
battery bank test.
After the nal starter pack
test, if the vehicle has an
auxiliary battery bank, the
user will be instructed to
disassemble the auxiliary
bank and test batteries
individually.
If the vehicle does not have
an auxiliary bank or when
the auxiliary bank nal test
is complete then the user
can proceed to the next test.
NOTE: If this is the rst pass or it a starter repair was
needed then the unit will go to the starter
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 rst and then the auxiliary bank.
FULL SYSTEM (BATTERY BANK TEST)

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The BCT-460 will
instruct the user
to visually check
the starter cables
and connections.
The user must
check off to
proceed.
The BCT-460 will
conduct a starter cable
voltage drop test.
The BCT-460 will display
the results. If the voltage
drop is good the user will be
instructed to start the engine
The BCT-460 will
show the user how
to connect up to the
starter. The larger
red clamp goes
on the positive (+)
starter post. Larger
black clamp goes
on the negative (-)
starter ground. The
small red clamp
goes to the Battery
Bank positive (+).
The small black
clamp goes to
the Battery Bank
negative (-).
The BCT-460 will
make sure the
engine is off, if it
isn’t the following
screen will appear,
if it is press the
start button.
FULL SYSTEM (STARTER CABLE VOLTAGE DROP TEST)

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If the voltage drop is
high , the user will be
instructed to repair the
cable on the rst pass.
On the 2nd or later
tries the user is
given the option to
Accept “As Is” the
VDrop to continue
the test.
After the repair is
made the user will
need to repeat the
Voltage Drop Test.
FULL SYSTEM (STARTER CABLE VOLTAGE DROP TEST)