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-

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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 ButtonPower on: Push and hold button for 1 second

Power off: Push and hold for more than 5 secondsReboot/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 ButtonPower 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 FUNCTIONSControl Module

USB Type A

Status LED USB Type B Control Module Latch

Charging Port

Factory Use OnlyVoltage drop lead connectors

Temperature Sensor

BCT-460 I/O ItemsUSB 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 zoneDate 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.

2Follow 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-

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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