To bypass a faulty relay in a NOCO jump starter, you can carefully jump the relay terminals with a jumper wire or replace the relay altogether to restore proper function.
NOCO jump starters are reliable devices that help you get your vehicle started when the battery is dead, but like any electronic device, they can develop faults over time. A common issue is a faulty relay, which prevents the jump starter from delivering power to your car’s battery.
Before attempting any bypass, it’s important to understand the risks involved, including potential electrical hazards or damage to your jump starter. Bypassing the relay should be a temporary solution or done only if you are confident in your electrical skills.
Best NOCO Products for Maintaining and Troubleshooting Your Jump Starter
When working with a faulty relay in your NOCO jump starter, having the right tools and accessories can make all the difference. Here are the top three NOCO products that are essential for testing, maintaining, or replacing parts in your jump starter:
NOCO Genius5 Battery Charger and Maintainer
This versatile charger is perfect for keeping your jump starter’s battery healthy. It offers smart charging with multiple modes to diagnose and maintain batteries, ensuring your NOCO jump starter performs optimally.
NOCO Lithium Jump Starter GB40
If your current jump starter relay is faulty beyond repair, the GB40 is a reliable backup. It features advanced safety features and a powerful lithium-ion battery, making it a top choice for jump-starting most vehicles.
NOCO Genius Boost Plus GB40 Portable Lithium Jump Starter
An upgrade to the original GB40, this model offers enhanced power delivery and safety features. It’s compact, easy to use, and includes built-in diagnostic tools to help spot electrical issues like relay faults.
How to Identify a Faulty Relay in Your NOCO Jump Starter
Recognizing a faulty relay is the first step before attempting any bypass or repair. The relay in your NOCO jump starter acts as an electrical switch that controls the power flow from the battery to the vehicle. When it fails, your jump starter may not deliver power correctly, making it seem like the device itself is broken.
Common signs of a faulty relay include:
- No power delivery: The jump starter powers on, but it doesn’t send any current to the vehicle’s battery.
- Clicking sounds: When you try to start your car, you hear rapid or inconsistent clicking noises from the jump starter.
- Overheating: The jump starter or relay area may feel unusually hot due to electrical resistance.
- Intermittent operation: Sometimes it works, sometimes it doesn’t — a classic sign of relay failure.
To confirm the relay issue, you can use a multimeter to test for continuity or resistance across the relay terminals. If the readings are abnormal or there’s no continuity when the relay should be closed, the relay is likely defective.
Safety Precautions Before Attempting to Bypass a Relay
Bypassing a faulty relay in your NOCO jump starter requires careful attention to safety. Electrical components can pose risks such as electric shock, short circuits, or permanent damage to your jump starter if handled improperly. Before you start, keep these essential safety tips in mind:
Disconnect the jump starter from any power source
Always ensure the jump starter is turned off and disconnected from your vehicle or charger.
Wear protective gear
Use insulated gloves and safety goggles to protect yourself from sparks or accidental contact with live terminals.
Work in a dry, well-lit area
Avoid damp or cluttered environments to reduce the risk of electrical shorts and to see clearly what you’re doing.
Use insulated tools
Jumper wires or testing probes should have proper insulation to prevent accidental shorts or shocks.
Avoid bypassing for long periods
Bypassing the relay is a temporary fix; prolonged use can strain other components and cause further damage.
Know your limits
If you’re unfamiliar with electrical systems or uncomfortable performing these steps, consult a professional technician.
Step-by-Step Guide to Bypass the Faulty Relay in Your NOCO Jump Starter
Bypassing a faulty relay in your NOCO jump starter can get you back on the road quickly, but it must be done carefully. Follow these numbered steps to safely bypass the relay and restore power flow:
Step 1: Gather Your Tools
Before you begin, make sure you have a jumper wire (insulated), a multimeter for testing, and insulated gloves. Avoid using bare wires to prevent accidental shorts.
Step 2: Power Off and Disconnect
Turn off your NOCO jump starter and disconnect it from any charging source or vehicle. Safety is critical, so make sure there is no current flowing.
Step 3: Locate the Relay
Open the jump starter casing carefully to access the relay. Consult your NOCO model’s manual to find the exact location of the relay board inside.
Step 4: Identify Relay Terminals
Using the schematic or relay markings, identify the two main terminals of the relay responsible for switching power.
Step 5: Test Relay with Multimeter
Use the multimeter to test the relay’s terminals for continuity. If no continuity is found when the relay should be closed, the relay is faulty.
Step 6: Bypass the Relay
Take your insulated jumper wire and carefully connect the two relay terminals directly. This jump connects the circuit, allowing power to flow around the faulty relay.
Step 7: Reassemble and Test
Close the casing carefully without dislodging the jumper wire. Power on the jump starter and try jump-starting your vehicle. It should now deliver power as intended.
Step 8: Temporary Fix Reminder
Remember, this bypass is a temporary solution. Plan to replace the faulty relay or jump starter soon to avoid damaging other components.
When to Replace Your NOCO Jump Starter Instead of Bypassing
While bypassing a faulty relay can be a useful short-term fix, there are situations when replacing your NOCO jump starter is the smarter, safer choice. Understanding these scenarios helps you avoid further damage and ensures your vehicle’s reliable jump-starting when it matters most.
Signs you should replace rather than bypass:
Multiple component failures
If other parts besides the relay show signs of wear or damage (like the battery or internal circuitry), bypassing won’t fix the root problem.
Age and warranty status
If your jump starter is old or out of warranty, investing in a new model may provide better performance and safety.
Unstable or inconsistent power delivery
If bypassing doesn’t restore reliable operation or the device frequently fails, replacement is necessary.
Visible physical damage
Cracked casing, damaged cables, or corroded terminals mean the jump starter isn’t safe to use.
Cost of repair vs. replacement
Sometimes the cost of relay replacement and labor exceeds buying a new jump starter with updated features.
Modern NOCO jump starters, like the GB40 and Genius Boost Plus, come with advanced safety protections and powerful batteries that make them worthwhile upgrades. Ultimately, prioritizing safety and reliability over quick fixes will save you headaches and keep you prepared for any roadside emergencies.
How to Test the Relay in Your NOCO Jump Starter Before Bypassing
Before jumping straight to bypassing, it’s important to test the relay to confirm it’s actually faulty. This saves unnecessary work and helps you understand exactly what’s wrong with your NOCO jump starter.
To test the relay, you’ll need a digital multimeter and some basic knowledge of how the relay functions. Here’s a simple process:
- Step 1: Power off the jump starter and disconnect it from all sources. Safety first.
- Step 2: Locate the relay inside the jump starter casing — usually a small black or clear rectangular box mounted on the circuit board.
- Step 3: Set your multimeter to continuity mode or resistance mode.
- Step 4: Test the coil terminals: Place the multimeter probes on the relay’s coil pins. You should get a reading of a few hundred ohms indicating the coil is intact.
- Step 5: Test the switch terminals: Check for continuity between the normally open terminals. When the relay is not energized, these should show no continuity. If the relay is manually activated (if possible), these should close and show continuity.
- Step 6: Check for stuck contacts: If the relay shows constant continuity between switch terminals without activation, it might be stuck closed — a fault.
If any of these tests fail, the relay is likely defective and may need bypassing or replacement. Testing first helps you diagnose correctly, avoiding unnecessary work or damage.
Common Causes of Relay Failure in NOCO Jump Starters and How to Prevent Them
Understanding why relays fail can help you take steps to extend the life of your NOCO jump starter and avoid inconvenient breakdowns. Here are the most common causes of relay failure and practical prevention tips:
Electrical Overload
Relays control high current, and excessive load or repeated surges can cause internal contacts to burn or weld together, leading to failure.
Prevention: Avoid jump-starting vehicles with batteries or engines beyond your NOCO model’s capacity. Follow manufacturer guidelines strictly.
Moisture and Corrosion
Exposure to moisture or humid environments can corrode relay contacts and circuit boards, impairing electrical flow.
Prevention: Store your jump starter in a dry, cool place. Use protective cases and avoid exposing it to rain or dampness.
Mechanical Wear and Tear
Relays have moving parts that can wear out over time, especially with frequent use.
Prevention: Regularly inspect your jump starter for signs of wear and perform maintenance like cleaning terminals and connections.
Poor Quality or Manufacturing Defects
Occasionally, relays fail due to inherent defects or substandard materials.
Prevention: Purchase your jump starter from reputable sources like NOCO and keep warranty information handy for support.
Conclusion
Bypassing a faulty relay in your NOCO jump starter can be a practical, temporary solution when you need to restore power quickly. However, it’s important to correctly identify the relay issue, follow safety precautions, and understand that bypassing is not a permanent fix. Testing the relay first and knowing when to replace your jump starter entirely will save you time and prevent further damage.
Proper care and awareness of common relay failure causes can extend the life of your NOCO jump starter, ensuring you’re always prepared for roadside emergencies. Whether you choose to bypass or replace, prioritize safety and quality to keep your jump starter reliable.
Frequently Asked Questions About How to Bypass a Faulty Relay in a NOCO Jump Starter
Is it safe to bypass the relay in my NOCO jump starter?
Bypassing the relay can be safe if done correctly and temporarily. However, it involves working with electrical components, so following safety precautions—like disconnecting power, using insulated tools, and wearing protective gear—is crucial. For long-term use, replacing the faulty relay or the jump starter itself is safer.
How do I know if the relay in my NOCO jump starter is faulty?
Common signs include the jump starter not delivering power, clicking noises from the relay, or failing continuity tests with a multimeter. Testing the relay coil and switch terminals using a multimeter can confirm if the relay is defective.
Can I bypass the relay myself without professional help?
If you have basic electrical knowledge and follow clear instructions carefully, you can bypass the relay yourself. Always prioritize safety, and if unsure, seek help from a qualified technician to avoid damage or injury.
How long can I use a bypassed relay jump starter?
A bypass is a temporary fix designed to get your jump starter working until you can replace the relay or device. Prolonged use risks damaging other components and may void warranties.
What causes relays in NOCO jump starters to fail?
Relays may fail due to electrical overloads, moisture exposure, mechanical wear, or manufacturing defects. Proper storage, usage within limits, and regular maintenance help prevent failures.
Where can I buy replacement relays for my NOCO jump starter?
Replacement parts may be available through NOCO’s official website, authorized dealers, or specialized electronics suppliers. Always ensure compatibility with your jump starter model.