AutoMeter BCT-460NAV User manual

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BCT-460NAV
Operator's Manual
Hand Held-Accuracy with a Pulsed 120 Amp Load Heavy Duty
The BCT-460NAV 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-460NAV
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-460NAV:
The BCT-460NAV 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-460NAV is user friendly. It guides you through the test and
tells you what to do next.
Caution: The BCT-460NAV 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.
This appears during the 1st use of your new BCT-460NAV, and after
any software updates. Touch MORE to continue reading/reviewing the
agreement. Touch ACCEPT to continue to the testers home page. At the
end of the agreement, if you touch DECLINE, there will be a link you can
use to access this user agreement online, and for a printable version.
www.autometer.com/terms-of-use
User Agreement

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TABLE OF CONTENTS
Specications ...................................................................................... 2
User Agreement................................................................................... 2
Table of Contents................................................................................. 3
Safety ................................................................................................. 4
Inspection and Visual Check ............................................................... 5
Wireless Communication..................................................................... 6
Controls and Functions/Review Results/About ................................... 6-8
Set Up ................................................................................................. 9
Tester Conguration/Settings .............................................................. 10
Saving Data to USB Flash Drive ......................................................... 11
Hook Up............................................................................................... 12
Heavy Duty PM Test ............................................................................ 13-16
Full System Tests ................................................................................ 17-24
Light Duty PM Test .............................................................................. 25-27
Individual Tests
Battery Test .............................................................................. 28-30
Starter Test ............................................................................... 31-34
Alternator Test .......................................................................... 35-37
Voltmeter .................................................................................. 42
Current Probe`.......................................................................... 42
Voltage Drop Tests
Starter Cable Test..................................................................... 38
Charging Cable Test................................................................. 39
Generic Cable Test................................................................... 40-41
Magnetic Circuit........................................................................ 41
Voltage Drop Test Results ........................................................ 41
Using the Optional Current Probe ....................................................... 42
Trouble Shooting ................................................................................. 43-44
Warranty .............................................................................................. 45
Contact Information ............................................................................. 46
Note: The BCT-460NAV performs a complete electrical system test that checks
the battery pack, 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-460NAV
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-460NAV 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
This device is only to be used on 12V and
24V electrical systems. Not for use on high
voltage electrical systems.
WARNING!

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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-460NAV 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 the vehicle.
The BCT-460NAV 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-460NAV 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-460NAV 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
Control Module Power Button
Briefly touch to wake up screen.
2 second push and hold to power
unit off or restart. 3 to 4 second
push and hold to turn unit on, if unit
is off.

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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-460NAV 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. See page 10
for settings.
USB Type A - This port is used to connect USB memory
sticks to save test data. 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.
Touch Review Results
screen which shows a
list of the tests that have
been done and allows
the user to view all the
details of the test.
Touch the 3 dots at upper
right corner, then touch
Check for Update which
allows the user to update
both the Control modules
application or the Load
module firmware.
Touch the 3 dots at
upper right corner,
then touch Battery
Status to show 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 Set 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. Check WiFi and Server Connection.
11. Force upload of individual and complete system tests.
12. Screen Brightness.
13. Opens Tester Configuration Screen.
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Touch the 3 dots to open the menu below

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TESTER CONFIGURATION
1. Dealer 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 information settings for
Navistar.
4. Temperature °F or °C.
5. Check to use previously tested Battery Type.
6. Set to default to use previously used battery
rating unit. Clear to use default rating value.
7. Set to default to use previously used rating
value. Clear to use default rating value.
8. Set to show a Near End of Life result. Clear to
show only Good and Bad battery result.
9. “Default CCA” Value.
10. Set to show health of Reserve Capacity on
Group 31 Standard/Flooded Batteries
11. Check to enable sending data to other
services.
12. Choose language for tester.
13. Wi-Fi Setup.
14. Date and Time Setup.
15. Advance Setup
16. Select print device.
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To access, from home
screen touch settings

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SAVING DATA to a USB FLASH DRIVE
6. Wait a few seconds for the USB ash drive to be
detected. The screen to the left will be displayed.
7. Choose SAVE DATA and press OK.
8. Choose data format and press SAVE.
9. Wait 10 seconds and remove USB ash drive.
1. Control Module must be docked to Load Module.
2. Tester must be disconnected from all charging
sources.
3. Start from Main Menu.
4. Make sure Control Module and Load Module
are “Connected” as shown in upper left of the home
screen. (See Picture Below)
5. Plug USB ash drive into connector on the right side
of tester.

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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 sides 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
Clean Clamps Corroded Clamps
Note: Brass battery terminal adapters must be used
when performing individual battery tests.
See page 44 for list of available adapters

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HEAVY DUTY PM TEST
The Heavy Duty PM test is intended to only be used during a time when the vehicle is in the shop for a Preventative
Maintenance service.
Touch
Heavy
Duty PM
Test.
Read
warnings
then
touch OK
Enter the
number of
batteries
in the
pack then
touch
OK.
Enter the battery
information.
When you enter
BATTERY TEMP,
the following
screen will
appear.
Connect the
large leads/
clamps.
Single Battery
Hook Up
Enter the
vehicle infor-
mation, then
touch OK.
Also choose
whether you
are going
to use the
Current
Probe for
additional
charging
information.
Aim the back of
the tester Load
Module at the bat-
tery for temper-
taure reference
then touch save
Press START
to begin the
test.
Connect
the large
leads/
clamps.
Multi Bat-
tery Hook
Up
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HEAVY DUTY PM TEST (cont.)
This screen
shows the proper
connections.
The Current
Probe will only
show if it was
chosen earlier.
This screen
only shows for
the Current
Probe option.
Touch Enter to
continue.
Enter the rated
output of the
alternator, then
touch Done.
Then touch
START.
Please
wait
a few
moments
until the
battery is
tested
The battery
test results
are then
displayed.
Touch
PROCEED
TO STARTER
TEST icon.
Skip to
image 16 if
no Current
Probe
selected.
If the Current
Probe option
was chosen,
this screen
will appear.
Touch the
Ok icon.
This screen
will NOT
appear if
the Current
Probe was
not chosen
earlier.
Start the
Engine
Follow the
on screen
prompts,
then touch
OK.
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HEAVY DUTY PM TEST (cont.)
Return to Idle.
Touch OK.
If more
information is
needed, this
screen may
appear.
Choose the
number of
cylinders, then
touch OK.
If more
information is
needed, this
screen may
appear.
Choose engine
type, and
displacement,
if diesel then
touch OK.
Follow the
on screen
prompts.
The charging
system is
now being
tested.
Running
Starter Test.
Follow the
on screen
prompts.
Rev Engine
and hold
RPM.
The test is
nished. Turn off
the engine, and
touch OK.
Starting System
results.
Touch MORE
RESULTS to view
Alternator Results.
Charging results
(with current probe
used)
Also shows output
charging current
and Vdrop results.
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Charging results
(with no current
probe used).
This will show
voltage regu-
lation & diodes
results.
Touch exit to
continue.
Test Summary
will now be
displayed.
Touch Next,
this will bring
you back to the
home screen.
HEAVY DUTY PM TEST (cont.)
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FULL SYSTEM TEST
Touch Battery
Rating box to
enter value.
Touch Bat-
tery Type to
choose type.
Touch Mea-
sure Battery
Temp
Electrically
separate the
batteries for
individual
testing, then
touch OK.
Enter the
vehicle
information,
then touch
DONE. Also
choose
whether you
are going to
use the Cur-
rent Probe
to eliminate
the need
for connec-
tions at the
starter, and
for quicker
testing.
Check off as
you inspect.
Once
checked, Ok
will appear.
Touch Ok to
continue.
Choose any
that apply,
then touch
Next.
Choose the
total number
of batteries.
If only one
battery was
chosen,
you will skip
steps 7 & 15
thru 20.
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10
Connect as
shown, then
touch Ok.
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Answer
(touch)
Yes or
No to
continue.
From
Home
Screen
touch Full
System
Test
The Full System Test is intended to be used in Heavy Duty applications where there is a suspected electrical system fault.
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FULL SYSTEM TEST
Connect
both sets
of leads
as shown,
then touch
Continue.
Touch Start
Battery Test
If earlier you
chose that
the vehicle is
equipped with
more than 1
battery, you will
now repeat test
for all batteries.
Once selec-
tion and
temperature
have been
chosen,
touch Start
Battery Test
to continue.
The battery
test will the
begin, and be
in Process.
Please Wait
When all
batteries have
been individ-
ually tested,
you will now
reassemble the
battery pack,
then touch OK.
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Choose how
many batteries
were replaced
then touch OK.
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Here are
your battery
results.
Touch next to
continue.
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Follow
prompt and
touch Save
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FULL SYSTEM TEST
If more
information is
needed, this
screen may
appear.
Choose
engine
type, and
displacement.
If diesel, then
touch OK.
Perform
inspection,
correct any
found issues,
then check
the box, and
touch OK.
Touch the red
enter box, to
enter the rated
output of the
alternator. Then
touch start.
Choose the
number of cyl-
inders, then
touch Ok.
Repeat,
same as
above, but
for charging
system.
If not using
Probe, skip to
page 6, under
heading of
“Testing W/O
Probe, (at
step 41).
Follow on
screen prompt,
then touch Ok.
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Follow on
screen
prompt.
The tester
will recognize
when the
engine is
cranked and
started.
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Follow this
diagram.
Probe
placement is
important for
proper results.
Be sure it is
placed on the
cable between
the battery
pack, and
starter.
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Battery
pack
results.
Touch next
to continue.
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FULL SYSTEM TEST
Turn off
engine then
touch Ok.
Please wait.
No action
needed.
Review
results then
touch NEXT..
Review
results then
touch Ok.
Follow on
screen
prompt.
Please wait
Review
results, then
touch EXIT for
Summary.
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Review
results, then
touch MORE
RESULTS.
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Once idling
touch Ok.
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Please wait.
No action
needed.
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