TECGAUSS BT010 Bedienungsanleitung

USER MANUAL

BT010

ELECTRONIC AUTO PARTS TESTER

www.gauss.com.br

Summary PAGE

1. Introduction 25

2. Auto Parts Tester Description 26

2.1 Sensor Testing Module 27

2.2 Power Supply Testing Module 27

2.3 Regulator Testing Module 27

2.4 Ignition Coil/Module Testing Module 27

3. Testing Methods 28

3.1 Sensor Testing 28

3.2 Tests with the Power Supply Module 28

3.2.1 Lamp Testing 28

3.2.2 Horn Testing 29

3.2.3 Alternator Rotor Testing 29

3.3 Alternator Regulator Testing 29

3.3.1 Use of PD/PWM Driver 30

3.4 Ignition Module Testing 30

3.4.1 Use of Auxiliary Coil 31

3.4.2 Ignition Coils 31

3.4.3 Using the Kilovolt Meter 31

3.4.4 Using the Logical Tip 31

3.5. Other Tests 32

3.5.1 Flasher Relay Testing 32

3.5.2 Relay Testing 32

3.5.3 Diode Testing 33

3.5.3.1 Individual Diode 33

3.5.3.2 Rectier 33

4. Warranty 33

Electronic Auto Parts Tester Manual BT010

1. INTRODUCTION

The BT010 Electronic Auto Parts Tester was

especially designed to test components of the electrical

and electronic systems in motor vehicles.

The following automotive components can be

tested:

• Sensors that provide variable voltage, variable frequency

and pulse signal. Some examples of these sensors are:

TPS, EGR, MAF, CKP, temperature sensors, magnetic

sensors, Hall sensors, fuel level meters, etc.

• Electronic or electromechanical regulators for alternator,

12 or 24 Volts, type A or type B, common or controlled by

the ECU type PD or PWM. BSS and LIN type regulators

controlled by the ECU (Electronic Control Unit) can be tes-

ted to check the stand-alone adjustment voltage

• Electronic ignition modules controlled by a pickup coil or

by the vehicle’s ECU

• Electronic or contact breaker points ignition coils. This

allows for testing coils with built-in ignition module, and

coils with two, four or six high-voltage outputs. In addition

to the high-voltage spark gap test, a kilovolt meter is also

available to measure the output voltage from the coil and

reach a more accurate diagnosis of the status of the igni-

tion coil

• Electrical parts that require DC power supply in the 12

or 24 Volt range, such as: common and halogen lamps,

horns, alarms, electric fans, windshield wipers, etc.

• Other electrical parts, such as: alternator rotors, alterna-

tor rectiers, rectier diodes, light and horn relays, asher

relays, starter motor auxiliary relays, oil sensors, etc.

It is NOT possible to test alternators or starter mo-

tors with this equipment, because they are parts that re-

quire a special condition and high operating currents that

cannot be supplied by the Tester’s internal power supply.

Fuel pumps can be powered with the Tester, but it must

be taken into account that for proper testing a mechanical

assembly is required that allows for measuring ow, pres-

sure and current.

The Tester works with 110/220 Volts AC power

voltage. The voltage should be selected with the switch

at the back of the equipment, which comes set to 220V by

default.

The Tester is delivered with the following wiring

harnesses and testing accessories:

1.1. A set of cables for tests using the power supply (PU01):

1.2. A set of cables for testing ignition coils or sensors

(PU02):

1.3. An accessory for testing regulators controlled by the

vehicle’s ECU:

1.4. An auxiliary coil for testing ignition modules and pro-

pulsion coils (BA01):

6Electronic Auto Parts Tester Manual BT010

1.5. A high-voltage probe (KV40):

NOTE: The high-voltage probe (KV40) is installed at the

back of the Tester.

1.6. An auxiliary lamp for testing regulators, asher relays

and others (LA01):

1.7. An auxiliary resistor, for testing Hall type sensors

(RA01):

1.8. A wiring harness for regulator testing (RM01):

IDENTIFICATION OF THE REGULATOR TESTING HARNESS (RM01)

TEST TIP

COLOR COLOR SYMBOL USED NAME

RED D+ Triodiode

GREEN B+, S, IG Positive from Battery

BLACK D- Ground

YELLOW DF Field

ORANGE L Lamp

BLUE W, V Stator

1.9 A wiring harness for ignition module testing (RM02):

IDENTIFICATION OF THE MODULE TESTING HARNESS (RM02)

TEST TIP

COLOR COLOR SYMBOL USED NAME

RED B+ Positive from Battery

BLACK Ground Ground

ORANGE + Signal Distributor Signal

VIOLET - Signal Distributor Signal

GREEN Coil Negative from Coil

BLUE Sensor Logical Tip

The testing harnesses are installed at the front of

the equipment, using the corresponding connector. These

are not interchangeable, so there is no possibility of error

in the connection. It is important to note the right position

of the harness connectors. They should enter smoothly. If

you try to connect them in reverse position or force them

in, the connection pins may be damaged.

NOTE: The catalogue of images with detailed testing infor-

mation for each element is available at

www.gauss.com.br/en/bt010.

Electronic Auto Parts Tester Manual BT010

2. AUTO PARTS TESTER DESCRIPTION

It is advisable to read the content of this manual

before using the Tester. The four main testing modules that

make up the equipment will be described in this section:

• Sensor Testing Module

• Power Supply Testing Module

• Regulator Testing Module

• Ignition Coil/Module Testing Module

2.1 Sensor Testing Module

It consists of a 2x16 character LCD screen, three

plugs and a push button, allowing for testing the sensors

as described in section 3.1 - Sensor Testing.

2.2 Power Supply Testing Module

This consists of a DC power supply with 12 and 24

Volts, with maximum current capacity of 10 Amperes.

This module has a digital screen that shows the voltage

(Volts) or current (Amperes) provided. Right beneath the

digital screen is a switch for change the unit of measure

between “VOLTS” and “AMPS”.

NOTE: In case of short-circuit, the power supply is imme-

diately deactivated to prevent damage. To reactivate it,

press the “POWER SUPPLY/RESET” button.

When the Tester is turned on, the power supply

testing module will be deactivated. To turn it on, press the

“POWER SUPPLY/RESET” button. The default start-up

voltage is 12 Volts. To switch to 24 Volts, press the corres-

ponding button.

2.3 Regulator Testing Module

The regulator testing module consists of:

• Red button, “ALTERNATOR REGULATOR” – starts up

the regulator testing module. To exit, press the “POWER

SUPPLY/RESET” button

• “TYPE A” and “TYPE B” switch – selects the type of regu-

lator eld to be tested

• “TEST” switch – hold it down to perform the test on the

regulators

• LEDs in the colors yellow, green and red identied as:

“LOW, NORMAL, HIGH” – serve to determine the voltage

range of the regulator (“SET POINT”)

• 25-pin connector for connecting the regulator testing har-

ness (RM01)

• “FIELD” lamp – works like the alternator rotor and allows

for observing the control performed by the regulator

• “PILOT” lamp – works as the lamp on the dashboard of

vehicles and indicates a failure in the loading system

NOTE: The rated voltage of the regulator is selected with

the “12” or “24” Volts buttons on the power supply testing

module. The adjusted voltage of the regulator is shown on

the digital screen, on the left side.

To end the test with regulators, press the “POWER

SUPPLY/RESET” button.

2.4 Ignition Coil/ Module Testing Module

The Ignition Coil and Ignition Module testing mo-

dule only operates at 12 Volts. In order to enter this mo-

dule, the Tester must be in starting condition, in which the

power supply is at 12 Volts and the regulator testing modu-

le is deactivated.

This module consists of the following parts:

• “MODULE/COIL” button – allows for starting up the tes-

ting system. To exit, press the “POWER SUPPLY/RESET”

button

8Electronic Auto Parts Tester Manual BT010

• 25-pin connector - connection for the ignition module

testing harness (RM02)

• “SPEED” switch – allows for reducing or increasing

signal frequency, simulating the speed variation in the

vehicle

• “SIGNAL SELECTOR” switch – allows for selecting the

type of input signal for operating the ignition module

o Position 1 – magnetic “PICK-UP” signal

o Position 2 – “HALL” e󰀨ect signal

o Position 3 – default “RENAULT” signal

o Position 4 – default “DELCO-DIS” signal

The testing method is described in section 3.4 of this

manual

• Spark Gap - allows for observing the high-voltage spark

when testing the ignition coils and modules

• “R/EXT”, “R/INT” and “NEG” plugs – connection for

cables for testing the ignition coils (PU02)

• High-voltage cable for testing the ignition coils

• 3-pin DIN type connector – High-Voltage Probe

connection (KV40)

• High brightness LEDs – allow for analyzing some ignition

module output signals, testing optical sensors and Hall

type signals built into the modules

• Digital screen – indicates the high-voltage value (in Kilo-

volts) generated by the tested ignition coil

NOTE: If a short circuit occurs between the RED and

BLACK test tips of the module testing harness (RM02), the

power supply will be deactivated immediately to prevent

damage. To reactivate the ignition coil and module testing

module, press the “POWER SUPPLY/RESET” button and

then the “MODULE/COIL” button.

3. TESTING METHODS

3.1 Sensor Testing

This module allows for testing sensors with va-

riable voltage or variable frequency signals. In addition, it

allows for checking the output signal from the regulators

controlled by the vehicle’s ECU and the output signal to

the tachometer in some ignition modules.

The sensor testing module is always active, so

that it can be used by other testing modules of the equip-

ment.

To start the test, rst select the type of signal to be

measured: Variable voltage or variable frequency.

There are three plugs: RED, reference voltage +5 Volts;

GREEN, input signal to be measured, and BLACK, ground

signal.

The procedures to test each type of sensor can be

found on the website www.gauss.com.br/en/bt010

3.2 TESTS WITH THE POWER SUPPLY MODULE

The power supply allows for testing automotive

parts that require 12 or 24 volts for operation.

To use it, turn on the Tester, press the “POWER SUPPLY/

RESET” button and the green LED should light up. The

initial available voltage is 12 Volts. To change it to 24 Volts,

press the 24V button. The power output plugs (positive

and negative) are right beneath the “12V” and “24V” se-

lection buttons. They are used to supply power to the part

to be tested.

The digital screen shows the DC voltage or cur-

rent consumed. Right below the screen is a switch that

allows for select reading in Volts or Amperes.

ATTENTION: The maximum current capacity of the

power supply is 10 Amperes, so don’t test parts that

consume current above this threshold to avoid over-

loading the power supply, which could damage it.

The power supply has short-circuit protection. If

this occurs, to reactivate it, remove the short circuit betwe-

en the testing cables and press the “POWER SUPPLY/

RESET” button.

3.2.1 Lamp Testing

First select the voltage at the Tester power supply (12 Volts

or 24 Volts) that corresponds to the rated voltage of the

lamp, then connect the connection cables at the points

indicated below, remembering that incandescent lamps

have no polarity.

NOTE: To test halogen lamps with three terminals (two

laments), connect the connection cables for the “Low Li-

ght” test and then for the “High Light” test. If one of the

laments doesn’t light up, the lamp is defective.

If the voltage applied to the lamp does not match

the manufacturer’s specication, it may present low light or

immediately burn out.

Electronic Auto Parts Tester Manual BT010

ATTENTION: Remember to NEVER hold the halo-

gen light by its glass lamp. This could expose you to

serious burns when testing and damage the lamp.

Preferably, wear safety gloves and protective gog-

gles to prevent accidents.

3.2.2 Horn Testing

Select the voltage at the Tester power supply (12

Volts or 24 Volts) corresponding to the horn specication,

then connect the connection cables according to the ins-

tructions below.

NOTE: Electronic horn models have dened polarity at the

terminals and the correct connection to the power supply

must be followed for proper functioning. Horn sold in bass

and treble pairs should be tested separately to prevent

overloading and damage to the power supply.

3.2.3 Alternator Rotor Testing

To measure rotor consumption, select the “AMPS”

option on the power supply testing module and set the vol-

tage to the value for the rotor specication (12 Volts or

24 Volts). Connect the connection cables to the collector

rings on the rotor as indicated in the image below. Watch

the current consumption of the rotor on the digital display.

If the values are not close to 4.0 Amperes for 12-Volt al-

ternator rotors or 2.0 Amperes for 24-Volt alternator rotors,

the rotor is defective.

To check the condition of the rotor winding, rmly

connect the connection cables to the collector rings and,

with the power supply connected, remove one of the ca-

bles quickly, noting the spark that forms between the rotor

ring and the tip of the testing cable. The spark should be

bright and white. If the spark is very weak and accompa-

nied by yellow sparks, the rotor may have a defective win-

ding with shorted turns and should be replaced.

NOTE: If at any time you notice that the digital display has

a voltage other than 12 or 24 Volts, contact technical su-

pport and ask for a technical review of the Tester to check

the condition of the power supply, and do not use it. Re-

member that powering a component with voltage higher

than those designed can cause damage to the component.

3.3 Alternator Regulator Testing

First, nd the technical information for the model

to be tested on the website www.gauss.com.br/en/bt010:

• Press the “ALTERNATOR REGULATOR” button

• Select the rated voltage of the regulator (12 Volts or 24

Volts)

• Select the type of regulator: TYPE A or TYPE B. TYPE A

is when one of the alternator rotor power supply brushes is

permanently connected to the POSITIVE battery terminal

and TYPE B is when one of the alternator rotor brushes

is permanently connected to ground (NEGATIVE battery

terminal)

• Connect the testing harness (RM01) as indicated in the

instructions for each regulator, abiding by the colors cor-

responding to each function

• In regulators with a “LAMP” pin, the PILOT LAMP and

the YELLOW LED on the Tester’s “SET POINT” indicator

should light up

• Press and hold the “TEST” button during the regulator

test. Watch the digital screen to check the adjusted voltage

and compare it to the value informed for the model. Check

the “SET POINT” LEDs: GREEN LED indicates that the

adjusted voltage is within the NORMAL range (between

13.8 and 14.9 Volts), but there are exceptions duly shown

on the website. In regulators with lamp pin, the PILOT

LAMP should go out, indicating that the lamp control is

working properly. The “FIELD” lamp should light up and, in

some regulator models, a slight oscillation may be obser-

ved, demonstrating the eld current control

NOTE: Wait approximately 5 seconds for the reading to

stabilize. Some regulators have “LAMP” and “IGNITION”

pins and reversing the connection can cause damage to

the regulator being tested.

Regulators with "AUX" terminal - regulator signal

output terminal to control an auxiliary relay in addition to

the lamp. To observe this control, connect the auxiliary

lamp (LA01) supplied with the Tester between the orange

and black tips of the cable harness (RM01). Before perfor-

ming the test, the Tester's pilot lamp will light up and the

auxiliary lamp (LA01) will remain o󰀨. During the test, the

pilot lamp should turn o󰀨 and the auxiliary lamp (LA01)

should light up.

Regulators with "DFM", "FR", "LI" terminal - re-

gulator pulse output terminal to the vehicle's Electronic

Control Unit to inform about the regulator’s functioning. To

10 Electronic Auto Parts Tester Manual BT010

check its operation, use the sensors test module in the

Frequency function. Using the PU02 cable set, connect

the green tip to the "IN" input and the red tip to the "+

5V REF" input, then connect the green alligator clip to the

DFM, FR or LI terminal attached with the red alligator clip

(+ 5V REF). Perform the regulator test and, during the test,

the DFM (FR, LI) signal output frequency and the percen-

tage of the time that the signal remains high should appear

on the LCD screen of the sensors test module.

Regulators with "P", "W" terminal - regulator pulse

output terminal generally used for the vehicle’s tachome-

ter. To check its operation, use the sensors test module in

the Frequency function. Using the PU02 cable set, con-

nect the green tip to the "IN" input, and then connect the

green alligator clip to the "P" or "W" terminal. During the

test, the LCD display will show the output frequency to the

tachometer.

Regulators with "D", "PWM" terminal - this regu-

lator terminal is used by the vehicle's Electronic Control

Unit to control the voltage set point. The Tester is supplied

with a PD/PWM DRIVER that allows for testing this type

of regulator by simulating the signal sent by the Electronic

Control Unit to the regulator. To perform the test, follow the

procedure below:

• Connect the green cable of the DRIVER to the GREEN

cable of the regulator testing harness (RM01) and the bla-

ck cable of the DRIVER to the black cable of the harness

• Connect the white cable of the DRIVER to the "D" or

"PWM" terminal of the regulator

• If the regulator is a "PD" type, connect the blue cable of

the DRIVER to the "P" terminal of the regulator

• Connect the regulator testing harness (RM01) as indica-

ted on the instructions and perform the test

3.3.1 Use of PD/PWM Driver

The “PD/PWM” DRIVER is a device for testing re-

gulators controlled by the vehicle’s Electronic Control Unit.

To start the test using this device, select the con-

trol method corresponding to the regulator via the PD/

PWM switch. Connect the green and black cables to the

respective cables on the regulator testing harness (RM01).

Connect the white cable to the input pin and, when ne-

cessary, the blue cable to the output pin of the regulator,

corresponding to communication with the vehicle’s control

unit.

NOTE: Some regulators have di󰀨erent connections and

the identication of pins is available for each model indi-

vidually.

Switch “V1” and “V2” may be used to vary the

input signal to check whether the regulator is responding

to the selected control method.

The GREEN LED indicates the driver signal ou-

tput (simulating the electronic control unit) to the regulator

and the yellow LED indicates the regulator communication

signal output to the electronic control unit.

To perform operating diagnostics on the PD/PWM

Driver:

Test the “PWM” signal: Connect the green and bla-

ck cables to the respective cables on the regulator testing

harness (RM01). Activate the regulator testing module.

Connect the white wire to the blue wire of the driver. The

yellow LED should ash, indicating proper communication.

The green LED stays on.

Test the “PD” signal: Press the TYPE A button

on the regulator testing module. Connect the green and

black cables to the respective cables on the regulator

testing harness (RM01). Still on the regulator testing har-

ness, connect the black cable to the yellow cable. Hold

the “TEST” button down and observe the green LED that

should go out while the voltage increases, indicating pro-

per functioning of the “PD” signal.

3.4 Ignition Module Testing

First, nd the technical information for the model

to be tested on the website www.gauss.com.br/en/bt010:

• Press the “POWER SUPPLY/RESET” button to activate

the equipment’s power supply

• Connect the testing harness (RM02) as indicated for the

model, abiding by the colors corresponding to each modu-

le function

• Select the type of input signal corresponding to the mo-

dule being tested. Note: the type of input signal is indicated

in the module instructions on the website. The Tester has

four types of input signals: Signal 1 (Pick-up) is the signal

for modules controlled by magnetic e󰀨ect. Signal 2 (Hall)

is the signal sent by the electronic control unit to control

the ignition module. Signal 3 (Renault) is used in some

Renault ignition modules and signal 4 (Delco) is used in

some Chevrolet ignition modules

• Press the “MODULE/COIL” button to activate this testing

module. A high-voltage spark should appear in the spark

gap. To test the module at di󰀨erent speeds, press the

“SPEED” button up to increase the module tripping speed

and down to reduce speed. At the top of the “SPEED” but-

ton is a blinking yellow LED, indicating the trip output. If

there is no high-voltage spark in the spark gap, the module

is defective

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