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I built this wee 'doo-daa' for my wife's Car due to it erratically (and irritatingly) chosing not to start and due to it randomly cutting out at the most inconvenient of times (such as on the motorway, at traffic lights and on corners). Instead of using the 'tried and tested' kinetic repair method (ie: twätting it with a hammer) - I thought maybe a different approach wouldn't be a bad idea....for a change.
My Suzuki Gsx-R was recently being a bit of a drama-queen too (the poor girl broke a fingernail....one, two, three - awww), I found the test rig worked well with her little black boxes too.
Right then......
I used an old car fusebox to mount and test the 'offending' Relay of choice....makes for a bit of ruggedness and used a household junction box as casing. Power is supplied from a 13vdc wall-wart from a dead handheld drill and I reused it's battery charger's power socket too (got to look after the environment, eh?)
The first switch on the circuit's left is the power on/off toggle switch (SW1) which lights the left Red LED.
To SW1's right is a tactile switch (SW2) which is used to actuate the Relay.
The second LED from the left (Green) lights if the Relay's coil is functional (whilst pressing SW2).
The following two LED's (Green and Red) light when the Relay's contacts are doing what they are supposed to do.
LEDs used are rated for 2V @20mA and 13Vdc PSU @800mA.
The relays I've tested so far have a built-in over-current protective resistor - a resistor could be added to the curcuit if needed.
Quick afterthough: without too many drama this curcuit could be adapted to test other relays - such as those found in washing machines, tube amps, etc.
Geekies and Geekimen....enjoy and I hope this might be of use for some of you out there. Rock on! :)
Btw: beta diagnosis for the Car's behaviour was a 'knackered' fuel pump Relay or clogged fuel filter - turns out is was the fuel filter, but this is a nice tool to have in the workshop.
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