Flex-a-Lite 480 User manual

Through Core Mounting Instructions
(SEE DIAGRAM “A”)
1.Position the electric fan against the back of the radiator, and mark the holes for mounting.(Some
applications may have A/C condensers and/or transmission coolers on the front of the radiator.
Additional adjustments or modifications may be necessary for installation)
2. Rotate fan blades to make sure they are free of
obstructions.
3. With a small phillips screwdriver pass through the marked
holes, carefully spread the fins to allow easy passage for
the nylon bolts (4 for the single fan unit, 6 for the double
fan unit). Pass the bolts through the shroud holes then twist
the bolts through the radiator.
4. Slide the rubber washer, then the nylon washer onto the
nylon bolt and finger tighten nylon nuts until snug.
5. Once again, rotate fan blades to insure that they are free
of obstruction.
OR
Radiator Support Channel Or Frame Installation
(SEE DIAGRAM “B”)
1. Attach frame mounting brackets to fan using nylon bolts cut to 1". Use nylon nuts to secure.
2. Position fan to desired location, Mark holes on radiator channels or frame.
3. Rotate fan blades to ensure that they are free of obstructions.
4. On the marked hole locations, drill 13/64" holes.
5. Secure the fan to radiator using 1/4" self tapping screws.
6. Check again to be sure the fan blades rotate freely.
Electric Cooling Fan
Models 480 & 490
Installation Instructions
Diagram A
Diagram B
rev. 1-3-08 98480 Page 1 of 4

Wiring Instructions Model 480
Step 1: Locate mounting point for the VSC (variable speed control) unit
Locate a mounting point for the VSC near inlet side of the radiator. The control unit needs to be
placed within about 2' of radiator inlet hose. On the fender well next to the radiator may be a
convenient location. Attach the control unit using the screws provided.
Step 2: Wire the fan motors (refer to Wiring Diagram, below)
Using the large, non-insulated bullet connectors provided, attach a length of the thick (10 AWG) red
wire to the red motor wires at fan. Attach a length of the thick (10 AWG) black wire to the black
motor wires at the fan. Once the fan is in place, these will attach to the control unit. If mounting the
control somewhere in the engine compartment, leave enough wire to reach the control unit.
rev. 1-3-08 98480 Page 2 of 4
NOTE: Model 490 does not include a fan control unit; skip to page 4 of instructions
NOTE: For pusher configuration, flip the fan blades over and reverse
motor wire polarity (black motor wire positive, red wire negative).
3. Connect the fan wires to the VSC
Now begin wiring the motors to the VSC. Using the large butt connectors provided, connect the red wire
you attached to the fan motor wires in Step 2 to the yellow wire on the VSC. Connect the black wire from
the motor wires to the purple wire on the VSC. (see Diagram 5 below) NOTE: Failure to do this will
result in incorrect operation and damage to fan motors!
4. Connect power leads
Determine the length needed to run thick red and black wire from the VSC to the battery terminals and trim
appropriately. Crimp a large yellow ring connector to one end of the each wire and connect the black wire
to the negative (-) battery terminal, but do not connect the red wire yet. Using butt connectors, connect
the fuse holder provided inline with the red wire. The fuse and fuse holder will protect the fan motors and
your vehicle's electrical system from damage.
FOLLOW THESE INSTRUCTIONS CAREFULLY TO AVOID DAMAGING THE CONTROL
UNIT, FAN MOTORS, AND YOUR VEHICLE! WHEN CRIMPING WIRES, ALWAYS USE
A QUALITY CRIMPING TOOL (DO NOT USE PLIERS OR OTHER DEVICES).
WIRING DIAGRAM - MODEL 480 (PULLER CONFIGURATION)
Diagram 5 - Wiring detail for Model 480 fan

6. Ignition controlled power source
Locate fuse box. Find a circuit that is "hot " when the key is in the "ON" position. NOTE: DO NOT
use the DRL or brake/taillight fuse! Attach the included fuse tap to fuse. Attach a female connector
to the thin red wire included and connect to the fuse tap. Trim the wire so that it will reach the VSC.
Attach pink female connector to end of wire and connect to terminal #9 on VSC.
7. Fan operation with air conditioning
Locate the wires coming from the A/C compressor. Determine which wire is ground and which is
positive by using a volt meter. Connect the positive wire to the supplied thin green wire by use of a
piggyback connector. Determine length needed to reach VSC and trim to length. Attach a pink female
connector to the wire. If the A/C compressor is activated by a positive (+) signal, connect this wire to
terminal #8 on VSC. If it is activated by a negative signal, connect to terminal #7 on VSC.
8. Temperature sensor
Locate the temperature sensor. Gently push probe through fins in radiator as close to the upper
radiator hose as possible, leaving about ¼" of the probe protruding out of the core. The rubber cap
should be used when possible to insulate any of the probe coming through the front side of the radiator.
Determine length of wire needed to reach VSC. IMPORTANT: Strip the insulation back about 1" and
fold the wire onto itself to effectively double the thickness of the wire before connecting the pink female
connectors as shown in at right. Attach these wires to terminals #10 & 11 on the VSC. Both wires
need to be connected but it doesn't matter which wire goes to each terminal.
rev. 1-3-08 98480 Page 3 of 4
Wiring Instructions Cont'd. 480
Install the temp. probe near the
inlet hose, leaving about ¼" of
the probe protruding from the
core.
When crimping the temp.
probe wires, strip back the
insulation, then fold the bare
wire back on itself to double
thickness.
9. Manual Switch
If manual switches (Flex-a-lite #31148) have been purchased, attach them as follows: To override
engine temperature signal and turn fans off, connect the switch to terminal #5 on VSC to send a
negative (-) signal. To override engine temperature signal and turn fans on, connect the switch to
terminal #6 on the VSC so that a negative (-) signal is sent.

1. Turn ignition on. After 6 seconds, LED #L4 should light up. If not, check to make sure that there
is 12 Volts at terminal #9 on VSC. The delay is to allow starter to start the vehicle without the fans
drawing any power.
2. With your engine running, engage the A/C. The fans should come on and cycle with the A/C
compressor. LED's #L1, L3 and L4 should be lit when fans are running. If they do not turn on, verify
that the A/C clutch is engaged and make sure you have a positive signal when the clutch is engaged
at terminal #8 on the VSC. Shut off A/C and let engine continue to idle, or drive the vehicle a short
distance to bring the engine to operating temperature (monitor the vehicle's temperature gauge).
3. Verify that operating temperature has been reached by feeling the upper radiator hose. Hot water
should be flowing through hose into the radiator. If the fans have not cycled on yet, slowly adjust
the screw on the VSC until the fans cycle on. Turning the screw further in this direction will keep the
engine at a lower temperature, and turning in the opposite direction will keep the engine at a higher
temperature. NOTE: THE TOTAL MOVEMENT OF THE ADJUSTMENT SCREW IS ABOUT ¾
OF A TURN. TURNING THE SCREW BEYOND THE LIMITS WILL DAMAGE THE UNIT! Once
desired temperature is set, let the engine continue to idle and make sure the fans will cycle to
maintain desired temperature. When fans are running, LED's #L1 and L4 should be lit.
Initial Start-up and Adjustment Procedure
The Variable Speed Control has new features.
At the set temperature, the fans will come on
at 60%; this reduces the load on your charging
system. If the temperature rises, the fan speed
will increase. If your set temperature is 195°F,
then between 195° and 205° the fan speed will
increase from 60% to 100%. So after a 10-de-
gree rise from the set point, the fans will be
running at 100%.
The Flex-a-lite Limited Warranty
Flex-a-lite Consolidated, 7213-45th St. Ct. E. Fife, WA 98424, Telephone No. 253-922-2700, warrants to the original purchasing user, that all Flex-a-lite products to be free of defects in material and
workmanship for a period of 365 days (1 year) from date of purchase. Flex-a-lite products failing within 365 days (1 year) from date of purchase may be returned to the factory through the point of
purchase, transportation charges prepaid. If, on inspection, cause of failure is determined to be defective material or workmanship and not by misuse, accidental or improper installation, Flex-a-lite
will replace the product free of charge, transportation prepaid. Flex-a-lite will not be liable for incidental, progressive or consequential damages. Some states do not allow the exclusion or
limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and you may have other rights, which vary
from state to state.
The Flex-a-lite warranty is in compliance with the Magnuson-Moss Warranty Act of 1975.
rev. 1-3-08 98480 Page 4 of 4
1A. Model 490 puller configuration only: Wire the fan motors to power source (control unit or switch
and relay if desired). Connect the red wires from the fan motors to a 12v. positive (+) source. Connect
the black motor wires to a ground (-) source. NOTE: Failure to do this will result in incorrect
operation and damage to the fan motors!
1B. Model 490 pusher configuration: Wire the fan motors to a power source (control unit or switch
and relay if desired). Connect the black wires from the fan motors to a 12v. positive (+) source.
Connect the red motor wires to a ground (-) source. NOTE: Failure to do this will result in incorrect
operation and damage to the fan motors!
NOTE: For "pusher" configuration, the fan blade retaining clip must be removed,
and fan blade must be flipped over and reinstalled.
2. Connect the fuse holder. Be sure to connect the provided fuse holder in-line with the positive (+)
power wire to protect the fan motors and your vehicle's electrical system from damage.
Wiring Instructions - Model 490