Electric fan problems...

[SchnorrCS]

Hey everybody....
So I have a flex a lite black magic electric fan (Flex-a-lite 180 - Flex-a-lite Black Magic Xtreme Series Electric Fans - Overview - SummitRacing.com). I was controlling it with this Flex-a-lite 30332 - Flex-a-lite Adjustable Electric Fan Controllers - Overview - SummitRacing.com electric adjustable fan controller.

Something is badly wrong. This controller allows for thermostatic control as well as a manual over ride switch, both of which I have hooked up. I can't get the fan to trigger at all. I know all my connections are right, and I have power (full 12 volts) everywhere I should. Further, when I operate the manual override switch, I can hear the relay clicking so I know it's opening and closing right.

When it didn't work, I took the "brain box" out, and wired in a simple 40 amp relay (I believe the fan is max 18 amp draw) in place of the box. Still can't get it to come on. Again, I could hear the relay click, so I know I've got power and stuff.

Here's the kicker....
When I jumper wire the fan direct to the battery, the fan operates.

What gives? Is it possible that the fan motor is beginning to die, and when it gets the full amps from the battery, with no wiring, relays, or switches in the way, it'll go?

I've never even heard of this happening.
Oh, and I know the ground is good. I ground the paint off part of the radiator shroud, and grounded the fan there.

Thanks in advance...
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