Flex-A-Lite Model #295 Electric Cooling Fan
(4/29/2006)

Flex-A-Lite Model #295 Electric Cooling Fan Installation.
(4/29/2006)

Top Mounting Brackets
The top mounting brackets hold the shroud against the radiator core but do not carry any weight and are made of 1/16 x 3/4 aluminum flat stock.
Did not use any of the manufactures supplied mounting bracketry.
(4/29/2006)

Bottom Mounting Brackets
The bottom mounting brackets carry the weight and sit on the tray under the radiator. There are 4 (3 visible in picture) C shape brackets made of 1/16 x 3/4 aluminum flat stock.
Did not use any of the manufactures supplied mounting bracketry.
(4/29/2006)

Variable Speed Controller
The variable speed controller is mounted on the fan shroud.
Wiring is zip tied to the shroud to keep them away from the fan blades.

The VSC also has overrides for Off, and High. However the A/C compressor negative signal input can be use for an override Low (assuming the temp doesn't have it on higher). But I don?t have any of the overrides wired up yet.

One of the things I really like about the Flex-A-Lite variable speed control system is that the fans are started gently so as not to create a huge current draw spike. Turning on the headlights creates a larger spike than this system does.
(4/29/2006)

Ground Connection
The ground connection is made to the factory ground post next to the battery at right front of engine compartment.
(4/29/2006)

Fuse Holder Mounting & Connection
The fuse holder is mounted next to the starter relay on the right fender.
The fuse holder is connected to the starter relay positive battery terminal.
(4/29/2006)

Ignition On Signal
The ignition on signal source is obtained from trailer battery charge relay. Connection is made by taping into the wire from underneath the auxiliary relay box. The small red wire is the ignition on signal for the electric cooling fan. The larger red wire is battery charge relay output going to power rock lights and air compressor.
(4/29/2006)

A/C Compressor On Signal
The A/C compressor on signal is sourced from the pressure switch connector.
Since this is a non critical signal, about 1-1/2 to 2 inches of insulation was removed to allow the bare wire to be sandwiched into the connector. (that’s just how much I hate those crimp on wire taps).
(4/29/2006)

Temperature Probe
The temperature probe is installed in the radiator core next to the coolant return port (upper hose returning coolant from motor). This is per manufactures installation instructions. We’ll see how well it works and its long term dependability. If not acceptable will fit up a direct coolant contact probe.
(4/29/2006)

As I suspected the radiator temperature probe method is the deal breaker for this electric fan conversion. Installation per manufactures instructions results in several issues.

1) Low speed driving, 2 – 15 MPH or so, provides enough air flow to keep the probe cool and prevent the fans from turning on even though there is not enough air flow to keep the engine from over heating. On a ~70 degree day.

2) Moderate speed driving, 20 – 30 MPH, pulling the grade of an ordinary logging road, provides enough air flow to keep the probe cool and prevent the fans from turning on even though there is not enough air flow to keep the engine from over heating. On a ~70 degree day.

3) Coolant exiting the radiator and cooling the transmission fluid can exceed healthy temperature for the transmission before the fans are activated.
(6/29/2006)

Why Conversion To Electric
For improved fuel mileage? You're kidding right. In a 6,000 lb. non aerodynamic vehicle you really think removing a belt driven fan with properly functioning clutch is going to make any noticeable difference? Not a chance.

For more power by eliminating the stock belt driven fan? You're kidding right. How much power do you think it takes to turn the stock belt driven fan with properly functioning clutch? Only about 1 HP at cruising speed would be my guess.

To turn it off for deep water? Getting close. That's probably one of the better reasons for converting to electric from the stock belt driven fan.

But the reason I converted to the electric fan was because it was a good time to do so since the stock belt driven fan clutch seized up and for the "cool" project factor.
(4/29/2006)

Flex-A-Lite Electric Cooling Fan Model #295 Operation.
(4/29/2006)