User Manual

Product Overview

This manual provides essential information for the installation, operation, and maintenance of your American Volt 160°F Electric Radiator Cooling Fan Thermostat Sensor. This product is designed to activate an electric cooling fan based on coolant temperature, ensuring optimal engine operating conditions.

The kit includes two 160°F automotive engine grounding fan switches, each featuring a 3/8" NPT brass thread-in temperature probe. These sensors are engineered to activate a fan at 160 degrees Fahrenheit and deactivate it at 145 degrees Fahrenheit, providing precise temperature control for your cooling system.

Figure 1: American Volt 160°F Thermostat Sensors. A pair of brass 3/8" NPT temperature sensors designed for electric cooling fan activation.

Key Features:

• 2-pack universal 160°F automotive engine grounding fan switches.
• 3/8" NPT brass thread-in coolant temperature probe.
• Activates fan at 160°F and turns off at 145°F.
• Universal fit for applications with available 3/8" NPT port.
• Threads into engine block, radiator, manifold, or water outlet.

Setup and Installation

Proper installation is crucial for the correct function of the thermostat sensor. Ensure the engine is cool before beginning installation.

1. Identify Installation Location: The sensor is designed to thread into any available 3/8" NPT port in the engine block, radiator, manifold, or water outlet. Ensure the chosen location provides accurate coolant temperature readings.
2. Prepare the Port: If replacing an existing sensor, carefully remove the old unit. Clean the threads of the installation port to ensure a secure and leak-free fit.
3. Thread the Sensor: Gently thread the 3/8" NPT brass temperature probe into the prepared port. Do not overtighten, as this can damage the threads or the sensor. A small amount of thread sealant (not included) can be used for a leak-proof seal, if necessary.
4. Wiring Connections: Connect the sensor to your electric cooling fan system. The sensor acts as a grounding switch. Refer to the wiring diagram below for a typical installation setup. Ensure all electrical connections are secure and properly insulated.
5. Refill Coolant: After installation, ensure the cooling system is refilled to the appropriate level and bled of any air pockets according to your vehicle's service manual.

Figure 2: Typical Wiring Diagram. This diagram illustrates a common setup for connecting the thermostat sensor to an electric cooling fan system, including a relay, battery, and circuit breaker. The sensor acts as a grounding switch for the relay.

Figure 3: NPT - American Standard Pipe Thread/Taper Guide. This guide provides information on NPT pipe sizes and their actual outside pipe diameters, useful for verifying the correct 3/8" NPT fitting.

Operating Instructions

The American Volt 160°F Electric Radiator Cooling Fan Thermostat Sensor operates automatically based on the coolant temperature.

• When the coolant temperature reaches approximately 160°F (71°C), the sensor will close its internal circuit, providing a ground signal to activate the electric cooling fan.
• Once the coolant temperature drops to approximately 145°F (63°C), the sensor will open its internal circuit, deactivating the electric cooling fan.

This cycle ensures that the engine's cooling fan engages only when necessary, helping to maintain optimal engine operating temperature and prevent overheating.

Maintenance

The American Volt thermostat sensor is designed for durability and requires minimal maintenance. However, periodic checks can help ensure its longevity and proper function:

• Visual Inspection: Periodically inspect the sensor and its wiring for any signs of corrosion, damage, or loose connections.
• Cleanliness: Ensure the sensor's probe tip is free from excessive buildup or debris that could impede accurate temperature readings.
• Coolant System Health: Maintain your vehicle's cooling system according to manufacturer recommendations, including regular coolant flushes and checks for leaks, as a healthy cooling system contributes to the sensor's accurate operation.

Troubleshooting

If you experience issues with your thermostat sensor, consider the following troubleshooting steps:

• Fan Not Activating:
  • Verify the engine coolant temperature is above 160°F using an independent temperature gauge.
  • Check all wiring connections for looseness or corrosion, especially the ground connection.
  • Test the electric fan directly to ensure it is operational.
  • Inspect the relay (if used in your setup) for proper function.
  • Ensure the sensor is properly grounded.
• Fan Always On:
  • Confirm the engine coolant temperature is below 145°F.
  • Check for a short circuit in the sensor's wiring or the sensor itself, which could cause it to remain grounded.
  • Inspect the relay (if used) for a stuck-closed condition.
• Inaccurate Temperature Readings:
  • Ensure the sensor probe is fully immersed in the coolant and not obstructed by air pockets or debris.
  • Verify the sensor is installed in a location that accurately reflects the engine's coolant temperature.

Important Note: It is highly recommended to test the sensor's activation and deactivation temperatures before final installation to confirm proper operation.

Specifications

Warranty Information

Specific warranty details for this product are not provided in the available documentation. For information regarding warranty coverage, please contact American Volt directly through their official website or customer service channels.

Customer Support

For technical assistance, installation questions, or any other inquiries regarding your American Volt product, please visit the official American Volt store on Amazon or their corporate website for contact information.

You can visit the American Volt Store on Amazon for more products and support resources.