Federal Signal Corporation SIGNALMASTER SM518A Bedienungsanleitung

2561263C

REV. C 407

Printed in U.S.A.

INSTRUCTION SHEET

FOR

SIGNALMASTER™ MODELS SM518A AND SM428A

SAFETY MESSAGE TO INSTALLERS

People’s lives depend on your safe instal-

lation of our products. It is important to

read, understand and follow all instructions

shipped with the products. In addition, listed

below are some other important safety in-

structions and precautions you should follow:

• To properly install this light: you must

have a good understanding of automotive

electrical procedures and systems, along

with proﬁciency in the installation and

use of safety warning equipment.

• When drilling into a vehicle structure,

be sure that both sides of the surface are

clear of anything that could be damaged.

• In order for the light to function proper-

ly, a separate ground connection must be

made. If practical, it should be connected

to the fusible link at the front fender

between the negative (-) battery terminal

and chassis ground. At a minimum, it

may be attached to a solid metal body or

chassis part that will provide an effective

ground path as long as the light system is

to be used.

• Locate light control so the VEHICLE and

CONTROL can be operated safely under

all driving conditions.

• Do not attempt to activate or deactivate

light control while driving in a hazardous

situation.

• You should frequently inspect the light to

ensure that it is operating properly and

that it is securely attached to the vehicle.

• File these instructions in a safe place and

refer to them when maintaining and/or

reinstalling the product.

Failure to follow all safety precautions and

instructions may result in property damage, serious

injury, or death to you or others.

I. GENERAL.

The Federal SignalMaster™ Models SM518A and

SM428A are economical, low wattage, directional light as-

semblies that are designed for use in a ﬂashing mode. Lens

colors available are: amber (standard), red, blue, green, and

clear.

These models provide two distinctive directional sig-

nals: left arrow and right arrow. In addition, an alternating

ﬂash pattern produces a warning signal for use when a di-

rectional signal may not be appropriate. When a directional

signal is selected, the lamps are individually illuminated

in a sequential sweeping motion until all eight lamps are

illuminated.

II. SPECIFICATIONS.

Input Voltage 11VDC to 16VDC.

Polarity Negative ground only.

Operating Temperature -30° C to +65° C.

Range

Standby Current Zero amperes.

+BAT Fuse 25 amperes.

Output Drive 8, 27 watt lamps.

Capability (Total)

Flash Rate:

Directional 35 patterns/min.

Warn 60 patterns/min.

Dimensions: SM518A SM428A

Height 2.6" 2.6"

Length 50.9" 42.0"

Depth 3.4" 3.4"

Cable Length 35' 15'

These lights are intended for secondary

warning only. They are not intended for use

as a primary warning system.

Before drilling holes in ANY part of a vehicle, be

sure that both sides of the mounting surface are

clear of parts that could be damaged; such as brake

lines, fuel lines, electrical wiring or other vital

parts.

3. Drill two holes at the previously scribed posi-

tion marks.

4. Secure the control head to the mounting sur-

face with two user-supplied sheet metal screws.

C. Electrical Connections.

Failure to observe this WARNING may result

in ﬁre, burns or blindness.

If shorted to vehicle frame, high current con-

ductors can cause hazardous sparks result-

ing in electrical ﬁres or molten metal.

If additional cable length is required, splice

the same gauge (or heavier) wire to the leads.

DO NOT connect this system to vehicle bat-

tery until ALL other electrical connections

are made and mounting of all components is

complete.

Verify that no short circuits exist, before con-

necting to the Positive (+) battery terminal.

1. Power Connections.

a. Route the red and black 14-gauge wires to

the power source. Ensure that the power source is capable

of supplying an additional 25-amperes.

b. Connect the black wire to a known good

chassis ground. This connection must be capable of supply-

ing 25-amperes.

c. Do not connect the red wire to the positive

(+) power source terminal at this time.

2. Control Head Connections.

a. Wrap the control cable’s stripped wire

ends with tape and route the cable to the control head

mounting location.

b. See ﬁgure 2. Crimp ﬁve 1/4" straight

terminals on the cable wire ends and jumper wire combina-

tion.

OFF

ON HAZARD

FEDERALSIGNALCORPORATION

290A2884

SWITCH

BRACKET

CHASSIS

GROUND LEAD

TO CHASSIS GROUND

SWITCH

ON/OFF/ON

SWITCH ON/OFF

DECAL

RED

NOTE:

GOLD

(NO. 3)

TERMINAL

ON TOP

Figure 1.

III. INSTALLATION.

The SignalMaster's circuitry can be damaged, or

destroyed, by static discharge. To prevent ESD,

observe anti-static procedures during installation.

A. SignalMaster Light Assembly.

Install the light assembly as described in the

instructions packed with the mounting kit.

B. Control Head.

When installing equipment inside air bag

equipped vehicles, the installer MUST ensure

that the equipment is installed ONLY in areas

recommended by the vehicle manufacturer.

Failure to observe this warning will reduce

the effectiveness of the air bag, damage the

air bag, or potentially damage or dislodge the

equipment, causing serious injury or death to

you or others.

Assemble the control head as shown in ﬁgure

1. For proper operation of the unit, the switches must be

installed as shown. To install the control head, proceed as

follows:

NOTE

When selecting a mounting location for the control

head, it is necessary to keep in mind the Signal-

Master’s cable length. Plan wiring and cable rout-

ing before installation.

1. Select a mounting location for the control head

that allows the vehicle and controls to be operated safely at

all times.

2. Use the control head as a template and scribe

two drill position marks at the selected mounting location.

-2-

should be long enough to route from the light assembly to

the right, and left, turn signal lamp sockets.

b. Remove and retain the three screws

which secure the light assembly end plate at the cable exit

end.

c. Remove the end plate and slide the lens

mounting plate out about six-inches.

When connecting the right angle terminals to

connectors H1 and H2, support the circuit board

to avoid breaking the terminals or cracking the

printed circuit board.

d. See ﬁgure 3. Connect the two right angle

terminals to connectors H1 and H2. Note which wire is at-

tached to H1 and to H2.

e. Slide the lens mounting plate into the

extrusion. Route the 22-gauge wires through the grommet.

Secure the end plate on the light assembly using the previ-

ously removed screws.

f. Route each 22-gauge wire to the appropri-

ate turn signal lamp socket. Connect the wire from H2 to

the right turn signal lamp power wire. Connect the wire

from H1 to the left turn signal lamp power wire.

D. Inspection and Final Installation.

1. Ensure that there are no loose wire strands or

other bare wires which may cause a short circuit. Also, all

wires must be protected from any sharp edges which could

eventually cut through the insulation.

2. Connect the 14-gauge red wire to the (+) posi-

tive terminal of the battery using an in-line, user-supplied

fuseholder and 25A fuse. Locate the fuse as near the bat-

tery as possible to protect the entire length of wire.

NOTE

All directional lamps will illuminate simultaneous-

ly if the power supply leads are reversed. Correct

the wiring before proceeding.

3. Read and understand paragraph IV OPERA-

TION, and test for proper operation of all functions.

c. Connect the terminals on the switch as

shown in ﬁgure 2.

3. Illuminated Power Switch.

Improper wiring of the illuminated switch feature

will result in printed circuit board damage. Ensure

that the chassis ground lead is connected to the

gold (pin #3) terminal and that the unterminated

end of the lead is connected to a known good chas-

sis ground.

a. See ﬁgure 2. Connect the right angle

terminal on the switch bracket ground lead to the gold (pin

#3) terminal of the on-off switch.

b. Route the unterminated end of the ground

lead to a known good chassis ground. Cut the lead to length

and crimp the supplied ring terminal on the lead.

NOTE

If necessary, additional 18-gauge wire may be

spliced to the ground lead.

c. Secure the lead to the chassis ground with

a user-supplied screw.

4. Turn Signal Connections (optional).

a. Crimp the two right angle terminals on

one end of two user-supplied 22-gauge wires. The wires

-3-

Figure 2.

NOTE: TWO WIRES ARE

CRIMPED IN ONE TERMINAL

NOTE: MATING FEMALE TERMINALS ARE CRIMPED

ON WIRES BEFORE CONNECTING TO SWITCHES.

CONTROL CABLE

ASSEMBLY

BLACK

RED

290A2885B

WHITE

SWITCH BRACKET

REAR VIEW

JUMPER WIRE FROM

INSTALLATION KIT

GREEN

RED

GOLD

TERMINAL

OFF-ON

SWITCH

CHASSIS GROUND

HAZARD

SWITCH

321

CAUTION

IMPROPER WIRING OF THE ILLUMINATED SWITCH FEATURE

WILL RESULT IN P.C.B. DAMAGE. ENSURE THAT THE CHASSIS GROUND

LEAD IS CONNECTED TO THE GOLD (PIN #3) TERMINAL AND THAT

THE UNTERMINATED END OF THE LEAD IS CONNECTED

TO A KNOWN GOOD CHASSIS GROUND.

CONTROL CABLE

YELLOW

BLUE

CABLE TO LAMPS

BLACK

290A2886B

TURN SIGNAL RIGHT

TURN SIGNAL LEFT

H1 H2 H4 H5

RED RED +12V

RED +12V

(OPTIONAL)

(-)

(+)

Figure 3.

IV. OPERATION.

SAFETY MESSAGE TO OPERATORS

Peoples’ lives depend on your safe use of our

products. Listed below are some important

safety instructions and precautions you

should follow:

• Although your warning system is operat-

ing properly, it may not be completely ef-

fective. People may not see or heed your

warning signal. You must recognize this

fact and continue driving cautiously.

• Also, situations may occur which ob-

struct your warning signal when natural

or man-made objects are between your

vehicle and others, such as: raising your

hood or trunk lid. If these situations oc-

cur, be especially careful.

• At the start of your shift, you should

ensure that the light is securely attached

and all lamps are operating properly.

• If a selected function does not perform

properly or if any of the lamps remain il-

luminated when the control is off, discon-

nect the power connector from the con-

trol unit and contact the nearest service

center.

Failure to follow these safety precautions may

result in property damage, serious injury, or death to

you, to passengers, or to others.

RETAIN AND REFER TO THIS MESSAGE

A. On/Off Switch.

1. OFF Position.

The SignalMaster is not powered and the turn

signal/brake feature (if installed) is functional.

2. ON Position.

a. The switch will illuminate. If the switch

does not illuminate, check the switch bracket ground lead

for proper chassis ground connection.

b. The directional/hazard patterns will oper-

ate as selected by the Hazard Rocker Switch.

B. Hazard Rocker Switch.

NOTE

These patterns will override the turn signal/brake

feature (if installed).

1. LEFT Position.

In this position, the light produces a left arrow

ﬂashing pattern, instructing trafﬁc to move left.

2. CENTER Position.

In this position, an alternating pattern is pro-

duced. The four middle lights activate alternately with the

two outside lights on each side.

3. RIGHT Position.

In this position, the light produces a right ar-

row ﬂashing pattern, instructing trafﬁc to move right.

C. Turn Signal/Brake Option.

1. Turn Signal.

If installed, a single end lamp ﬂashes in sync

with the vehicle turn signal.

-4-

2. Brake.

If installed and the vehicle uses a common

brake/turn wire, both end lamps illuminate with the vehicle

brake lights.

Damage to the directional light assembly will occur

if this vehicle is jump-started when the light is

“on”. Ensure that the light is switched “off” before

jump-starting this vehicle.

V. MAINTENANCE.

A. General.

Crazing (cracking) of lenses will cause

reduced effectiveness of the light. Do not

use cleaning agents (which will cause craz-

ing) such as strong detergents, solvents, or

petroleum products. If crazing of lenses does

occur, reliability of light for emergency sig-

nalling purposes may be reduced until lenses

are replaced.

Ordinary cleaning of the plastic lenses can be ac-

complished by using mild soap and a soft rag. Should ﬁne

scratches or a haze appear on a lens, they can ordinarily be

removed with a non-abrasive, high quality, one-step, auto-

motive paste cleaner/wax and a soft cloth.

B. Lamp Replacement.

Use of higher wattage lamps can result in damage

to the colored lenses.

1. See ﬁgure 4. Remove and retain the two

screws which secure the lens. Carefully pull the lens

straight away from the light assembly.

Service life of lamp will be shortened if glass is

touched. If glass has been handled, clean with a

grease solvent.

A serious injury may result if lamp is touched

when hot. Always allow lamp to cool before

removing. Halogen lamps are pressurized

and if broken can result in ﬂying glass. Al-

ways wear gloves and eye protection when

handling the lamps.

-5-

2. Remove the defective lamp by carefully pull-

ing it out of the socket. Install a new lamp by aligning the

pins on the lamp base with the holes in the socket, and

carefully pushing the lamp into the socket.

Use of longer screws may damage the circuit board

assembly. Use the previously removed screws when

replacing the lens.

3. Replace the lens using the previously removed

screws.

VI. REPLACEMENT PARTS.

Description Part No.

Lens, Clear 8573001

Lens, Red 8573001-01

Lens, Amber 8573001-02

Lens, Blue 8573001-03

Lens, Green 8573001-04

Lamp, 27-watt halogen, 8573007

G.E. GH-22

Cable Assembly, 15-ft. 175846

Cable Assembly, 35-ft. 175846-01

Reﬂector and Terminal Assy. 8573180

Screw, Torx, #10-32 π7011163-04

PCB Assembly 2001228

Switch Kit Assembly 8573157

VII. SERVICE.

Communication and shipments should be addressed to:

Service Department

Federal Signal Corporation

2645 Federal Signal Drive

University Park, IL 60466

1-800-433-9132

290A2883

LENS

LIGHT

ASSEMBLY

REMOVE 2

TORX SCREWS

PULL LENS STRAIGHT AWAY

FROM LIGHT ASSEMBLY

CAUTION

THE USE OF LONGER SCREWS MAY DAMAGE

THE CIRCUIT BOARD ASSEMBLY. USE THE

PREVIOUSLY REMOVED SCREWS WHEN

REPLACING THE LENS.

Figure 4.

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