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Relay testing for Novice Technicians

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7 years 5 months ago #3329 by BigZ
Hey, guys just question for the relay testing methods. Automotive relays draw approx 120-150mA current draw. Is it safe to jump terminal between 30 to 87 to check current draw on relays itself and say fuel pumps that would draw 3-5 amps of current draw? :unsure:

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7 years 5 months ago - 7 years 5 months ago #3330 by Andy.MacFadyen
It is one of those tests that is very easy to make a mistake on and short the wrong terminnals. I tend to use a test light first. You can buy sets of test by-pass relays that have a selection of relay units fitted with external switches but these are fairly expensive where I am so I have made a couple of home made ones from junkyard parts.

" We're trying to plug a hole in the universe, what are you doing ?. "
(Walter Bishop Fringe TV show)



Last edit: 7 years 5 months ago by Andy.MacFadyen.

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7 years 5 months ago - 7 years 5 months ago #3357 by Dylan

It is one of those tests that is very easy to make a mistake on and short the wrong terminnals.


Totally agree with Andy. Gotta be careful.

I've done it many times but if you're not sure don't do it.
Last edit: 7 years 5 months ago by Dylan.

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7 years 5 months ago #3368 by Noah


This is a great video about troubleshooting a relay controlled circuit. Probably one of my favorite in recent history.
The 120ma current draw is just on the coil side of the relay, so jumping 30 and 87 would allow you to measure the current of the pump, not the relay itself.

"Ground cannot be checked with a 10mm socket"

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7 years 5 months ago #3369 by matt.white
That was a good refresher one Noah. Another that springs to mind was when Paul diagnosed the starter on his sons celica. He broke out the uactivate (spelling) relay bypass tool.

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7 years 5 months ago - 7 years 5 months ago #3371 by Noah
Yes, that's a handy tool. A bit pricey, but making relay testers from bit's of scrap takes some time and ingenuity. I've been considering abandoning my homemade ones for the U-Activate tester set.

"Ground cannot be checked with a 10mm socket"
Last edit: 7 years 5 months ago by Noah.

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7 years 5 months ago #3374 by Dylan
Yeah I considered buying one. But like Noah says it's a bit pricey.
Also like the Power Probe as you can see in the video:

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7 years 5 months ago #3387 by matt.white
Sorry I didn't bother with the link. I'm on here on my phone normally.

One feature I liked about the look of the uactivate was the loop for an amp clamp. I don't have one though. Still looks cool.

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7 years 5 months ago - 7 years 5 months ago #3392 by Andy.MacFadyen
I must confess I have unit for testing relays off car that I bought off eBay as an overstock/return item from Maplin (the UK equivalent of Radio Shack) for about 1/5 of the retail price. You connect it to the battery and plug a relay in, it cycles the relay 10 times and checks the coil and contact continuity. Of course it dosen't put the relay contacts under full working load curent.

www.maplin.co.uk/p/maplin-automotive-relay-tester-a19qx

" We're trying to plug a hole in the universe, what are you doing ?. "
(Walter Bishop Fringe TV show)



Last edit: 7 years 5 months ago by Andy.MacFadyen.

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7 years 5 months ago #3431 by Dylan

Sorry I didn't bother with the link. I'm on here on my phone normally.


No problem Matt!

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7 years 5 months ago #3437 by Tyler

matt.white wrote: That was a good refresher one Noah. Another that springs to mind was when Paul diagnosed the starter on his sons celica. He broke out the uactivate (spelling) relay bypass tool.


I'd LOVE to have one of those. And one of the Smart BOBs , too ;)

I've been getting by pretty well with this Lisle relay test set . Exactly like the ones featured in the Bad Engine Computer testing series. Very handy, but it's still possible to jump the wrong terminals if you're not careful.

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7 years 5 months ago #3451 by SLCDIAG

ASE Certified Master Automotive Technician + L1
ASE-5578-5149

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7 years 5 months ago #3471 by Dylan
Tyler wrote:

I've been getting by pretty well with this Lisle relay test set.


Nice man. But still + $120 :(

Why does everything have to be so expensive

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7 years 5 months ago - 7 years 5 months ago #3557 by FlyinHawaiian
I have the uActivate, it is kinda pricey. Haven't used it a lot yet but the times that I have, it's a pretty good tool. When I have the time, I'll run it through a bunch of tests and let you all know how it goes. But so far so good :woohoo:

I use this to test relays www.amazon.com/ESI-193-Black-Diagnostic-Relay/dp/B00NI10152

*shaka*
Last edit: 7 years 5 months ago by FlyinHawaiian.

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7 years 5 months ago #3569 by Dylan

When I have the time, I'll run it through a bunch of tests and let you all know how it goes.


That would be cool. Nice link by the way, like that relay tester.....

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7 years 1 week ago #8926 by Noah

Monde wrote: Hello
Does the pcm have anything to do in the starting system of this car? If the clutch switch when closed send a signal to the computer, there must be a reason for it, right?


Not sure what car you're referring to Monde :blink:
But, if the clutch switch is a PCM input, it's probably one of several inputs it must receive before the PCM will activate the starter relay.
I hope that's what you're asking about.

"Ground cannot be checked with a 10mm socket"
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7 years 1 week ago #8938 by Dylan
You mean the one I posted on page 2 here Monde?

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7 years 1 week ago #8954 by Dylan
The purpose of the clutch pedal switch circuit is for the PCM to monitor the position of the clutch pedal. This process is accomplished by reading the output voltage of the clutch position sensor. The clutch position sensor switch may vary in design from one vehicle to another, it is usually a basic "on/off" switch mounted near the clutch foot pedal on the support bracket. Regardless of the design, constant voltage is typically present on one side of the switch and the contacts are closed by engaging the clutch pedal transferring voltage to the starter or starter solenoid. This basic circuit and switch prevents starting the engine prior to engaging the clutch...
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