Federal Signal Corporation SIGNALMASTER 321102 User manual

2562094B
REV. B 407
Printed in U.S.A.
INSTRUCTION SHEET
FOR
SIGNALMASTER™ MODELS 321102, 321112, 321702, AND 321712
SAFETY MESSAGE TO INSTALLERS
People’s lives depend on your safe installation
of our products. It is important to read, under-
stand and follow all instructions shipped with the
products. In addition, listed below are some other
important safety instructions and precautions you
should follow:
• To properly install this light: you must have a
good understanding of automotive electrical
procedures and systems, along with proficien-
cy 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 any-
thing that could be damaged.
• In order for the light to function properly, 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 effec-
tive ground path as long as the light system is
to be used.
• Locate light control so the VEHICLE and CON-
TROL can be operated safely under all driving
conditions.
• Do not attempt to activate or deactivate light
control while driving in a hazardous situation.
• This product contains high intensity LED de-
vices. To prevent permanent eye damage, DO
NOT stare into the light beam at close range.
• You should frequently inspect the light to en-
sure 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 instruc-
tions may result in property damage, serious injury, or
death to you or others.
I. GENERAL.
The Federal SignalMaster is an economical, low wattage,
directional light assembly that is designed for use in a flashing
mode. Lens colors available are: amber (standard), red, blue, green,
and clear.
These models provide two distinctive directional signals: left
arrow and right arrow. In addition, an alternating flash pattern
produces a warning signal for use when a directional 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 (12V models).
22VDC to 28VDC (24V models).
Polarity Negative ground only.
Operating Temperature -30° C to +65° C.
Range
Standby Current Zero amperes.
+BAT Fuse 25 amperes (12V).
15 amperes (24V).
Output Drive 8, 27 watt lamps (12V models).
Capability (Total) 8, 20 watt lamps (24V models).
Flash Rate:
Directional 35 patterns/min.
Warn 60 patterns/min.
Dimensions: 51” 42”
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.
III. INSTALLATION.
The SignalMaster’s circuitry can be damaged, or de-
stroyed, by static discharge. To prevent ESD, observe
anti-static procedures during installation.
A. SignalMaster Light Assembly.
Install the light assembly as described in the instruc-
tions packed with the mounting kit.
B. Control Head.
When installing equipment inside air bag equipped
vehicles, the installer MUST ensure that the equip-
ment 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 SignalMaster’s cable
length. Plan wiring and cable routing 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.
CAUTION
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 position
marks.
4. Secure the control head to the mounting surface
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 conduc-
tors can cause hazardous sparks resulting in elec-
trical 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 battery un-
til ALL other electrical connections are made and
mounting of all components is complete.
Verify that no short circuits exist, before connect-
ing 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 supplying 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 loca-
tion.
b. See figure 2. Crimp five 1/4” straight terminals
on the cable wire ends and jumper wire combination.
c. Connect the terminals on the switch as shown
in figure 2.
3. Turn Signal Connections (optional).
a. Crimp the two right angle terminals on one
end of two user-supplied 22-gauge wires. The wires 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 mount-
ing plate out about six-inches.
When connecting the right angle terminals to the con-
nectors, support the circuit board to avoid breaking the
terminals or cracking the printed circuit board.
d. See figure 3. Connect the two right angle termi-
nals to connectors H4 and H5. Note which wire is attached to H4
and to H5.
e. Slide the lens mounting plate into the extru-
sion. Route the 22-gauge wires through the grommet. Secure the
end plate on the light assembly using the previously removed
screws.
f. Route each 22-gauge wire to the appropriate
turn signal lamp socket. Connect the wire from H4 to the right
turn signal lamp power wire. Connect the wire from H5 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.
OFF
ON HAZARD
FEDERALSIGNALCORPORATION
290A5167
SWITCH
BRACKET
SWITCH
ON/OFF/ON
SWITCH ON/OFF
DECAL
RED
NOTE:
NO. 3
TERMINAL
ON TOP
Figure 1.
Figure 2.
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NOTE: TWO WIRES ARE
CRIMPED IN ONE TERMINAL
NOTE: MATING FEMALE TERMINALS ARE CRIMPED
ON WIRES BEFORE CONNECTING TO SWITCHES.
CONTROL CABLE
ASSEMBLY
BLACK
BROWN
RED
290A5168B
WHITE
SWITCH BRACKET
REAR VIEW
JUMPER WIRE FROM
INSTALLATION KIT
GREEN
RED
NO. 3
TERMINAL
OFF-ON
SWITCH
HAZARD
SWITCH
3
2
1
321
CAUTION
IMPROPER WIRING OF THE ILLUMINATED SWITCH FEATURE
WILL RESULT IN P.C.B. DAMAGE. ENSURE THAT THE BROWN
LEAD IS CONNECTED TO THE PIN #3 TERMINAL.

2. Connect the 14-gauge red wire to the (+) positive
terminal of the battery using an in-line, user-supplied fuseholder
and 25A fuse (15A fuse for 24V model). Locate the fuse as near the
battery as possible to protect the entire length of wire.
NOTE
All directional lamps will illuminate simultaneously if
the power supply leads are reversed. Correct the wiring
before proceeding.
3. Read and understand paragraph IV OPERATION,
and test for proper operation of all functions.
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 operating
properly, it may not be completely effective.
People may not see or heed your warning sig-
nal. You must recognize this fact and continue
driving cautiously.
• Also, situations may occur which obstruct 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 occur, be especially careful.
• This product contains high intensity LED de-
vices. To prevent permanent eye damage, DO
NOT stare into the light beam at close range.
• 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 prop-
erly or if any of the lamps remain illuminated
when the control is off, disconnect the power
connector from the control 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 pas-
sengers, or to others.
RETAIN AND REFER TO THIS MESSAGE
H3 ( - ) BLACK GROUND TO CHASIS OR BATTERY
H2 RED +12V TO LIGHT HEADS
H1 RED +12V,
FUSED H4 RIGHT TURN SIGNAL (OPTIONAL)
H5 LEFT TURN SIGNAL (OPTIONAL)
CABLE TO LAMPSCONTROL CABLE
290A5169
Figure 3.
A. On/Off Switch.
1. OFF Position.
The SignalMaster is not powered and the turn sig-
nal/brake feature (if installed) is functional.
2. ON Position.
a. The switch will illuminate. If the switch does
not illuminate, check the connection of the brown control wire.
b. The directional/hazard patterns will operate as
selected by the Hazard Rocker Switch.
B. Hazard Rocker Switch.
NOTE
These patterns will override the turn signal/brake fea-
ture (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 produced.
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 arrow
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.
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 ef-
fectiveness of the light. Do not use cleaning agents
(which will cause crazing) such as strong deter-
gents, solvents, or petroleum products. If crazing of
lenses does occur, reliability of light for emergency
signalling purposes may be reduced until lenses
are replaced.
Ordinary cleaning of the plastic lenses can be accom-
plished 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, automotive paste cleaner/wax
and a soft cloth.
-3-

290A5170
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.
290A5185
LIGHT ASSEMBLY
LED MODULE
REMOVE TWO TORX
HEAD SCREWS
PULL THE LED MODULE
STRAIGHT AWAY FROM
THE LIGHT ASSEMBLY
Figure 5.
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 remov-
ing. Halogen lamps are pressurized and if broken
can result in flying glass. Always wear gloves and
eye protection when handling the lamps.
2. Remove the defective lamp by carefully pulling 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 as-
sembly. Use the previously removed screws when replac-
ing the lens.
3. Replace the lens using the previously removed
screws.
C. LED Module Replacement.
This product contains high intensity LED devices.
To prevent permanent eye damage, DO NOT stare
into the light beam at close range.
1. See figure 5. Remove and retain the two screws
which secure the LED module assembly.
2. Disconnect the right angle connectors and remove
the LED module assembly.
3. Observing polarity, connect the right angle connec-
tors to the appropriate printed circuit board connectors.
4. Install the new LED module assembly 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, 12V
Lamp, 20-watt halogen, 8573085
G4 Bi-Pin, 24V
LED Module Assy, White, 12V 8573229
LED Module Assy, Red, 12V 8573229-04
LED Module Assy, Amber, 12V 8573229-05
LED Module Assy, Blue, 12V 8573229-06
LED Module Assy, White, 24V 8573229-07
LED Module Assy, Red, 24V 8573229-08
LED Module Assy, Amber, 24V 8573229-09
LED Module Assy, Blue, 24V 8573229-10
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
Copyright 2007 Federal Signal Corporation
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