I'm having problems wiring my fan. I have 2 separate relays. The toggle has 3 poles (1 top pole, 1 center pole, & 1 lower pole. I wired both 85(ground) pins to the center pole & 86 pin to the top & lower poles. 30 pin comes from the positive battery. And 87 pin goes to fan motor. My fan does not come on at all. I think the problem may be my wiring at the toggle switch. I can't find a diagram for the on/off/on switch.
Your switch is not providing voltage to the coil side of the relay(s). Is your intention to use 1 relay for LOW and 1 relay for HIGH? If so: Disconnect whatever you have on the center switch pole and instead connect the center pole to ground. Make a jumper (small awg wire) from pin 30 over to pin 85 (each relay). Leave the upper and lower switch poles connected to each relay pin 86 (respectively). Leave each pin 87 connected to the LOW and HIGH wires of the fan motor (respectively). Make sure you have a fuse on the feed for pin 30 (both relays). If you need a drawing, I'm sure someone else or myself can sketch it up for you. Also, the Volvo relays takes care of this for you. PS: If you switch that Taurus fan to HIGH from OFF, you will have a significant initial current draw. Make sure you don't melt your HIGH speed relay.
Ok. Yes, that is what in trying to do. Im using to 75a relays. I never read anything about a jumper wire from pin 30 to pin 85. Will 14 gauge be an ok size? I just learned about the Volvo relays. I will have to che k some auto recycling yards on my next off day. Thanks so so much.
The jumper wire is giving a 12V+ feed for the + coil side of the relay(s). Then, using the switch, you are providing a ground to the - side of the coil. This allows the coil to close the relay contacts. You are kind of doing it this way: http://img.photobucket.com/albums/v668/dvdt/Cooling%20System/DualCoolingFanWiring.jpg You could actually wire yours up just like it, without using a 30 to 85 jumper. This diagram only allows the fans to operate with the key in the ON/RUN position (probably a good thing, unless you want to be able to run them when ever you want). Instead of thermo switches, you are providing a ground to the relay coils using a toggle switch. If you wire yours up the way it shows in the above diagram but instead use the top and bottom poles of the toggle switch (with the center pole connected to ground), you should get the results you want.
Ok, let me adjust the diagram for you... Here ya go: Keep in mind, the reason the previous diagram used 87a was to make it impossible to run the fan on LOW and HIGH at the same time (which could damage the fan motor). By moving to pin 30, you eliminate that safety. But, because you are using a toggle switch (instead of thermo switches), it should be mechanically impossible to operate the fan in both speeds at the same time, so you are kind of adding in a mechanical safety.
Ok. So the yellow wire that goes to both 30 pins(60 amp fan fuse) comes from where? Does the red wire that goes to both 86 pin come from the positive side of the battery? I have a fuse on that wire.
It is a fused direct battery connection. It needs to be a wire capable of supplying the required current that the fan uses on HIGH. No, that wire comes from the ignition switch. It should only have 12V+ on it when the ignition switch is in the RUN position. If you choose not to use a switched source, and instead just give it 12V+ directly from the battery, then that means the relays will work (and subsequently the fan) and allow you to run the fan whenever you want using the toggle switch, regardless of the ignition position. If that is what you want, then don't forget to turn the fan OFF or you will be stranded with a dead battery.
So the yellow wire is the fused wire from the battery. That will be my 8 gauge wire. How thick does the red wire need to be? I guess the red wire does not need a fuse?
The red wire can be 18 awg. I would fuse it at 5A. It only carries enough current for two relay coils.
Thanks a lot. I think I have an understanding now. It doesn't seem complicated but maybe it is just a little.
After I got this to work. I didn't like the way it looked. I didn't like all the wires. So I found a Volvo relay in they salvage yard. The wire from my fuse is 8 gauge, the fan wire to the 30 relay is maybe 12 gauge, is it ok to use a 12 gauge wire or stay with the 8 gauge wire?
You can go with the 12ga as long as your total length of 12ga (power and ground) is less than 4ft or so. I would fuse it at 50A and see how it works. As long as you go from LOW to HIGH (and not OFF immediately to HIGH), the HIGH surge current will be less than 50A. The Taurus fan should run on HIGH at about 35A. Here is a handy chart (uses 10% drop allowance): http://www.hitmanhotrods.com/en/admin/sources/editor/assets/chartsGraphs/wire_sizing_chart2_titled_filled.jpg
