Federal Signal Corporation SIGNALMASTER SM428A-NFPA User manual

2561472A
REV. A 898
Printed in U.S.A.
INSTRUCTION SHEET
FOR
SIGNALMASTER™ MODELS SM428A-NFPA AND SM518A-NFPA
SAFETY MESSAGE TO INSTALLERS
People’s lives depend on your safe installation 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 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 proficiency in the installa-
tion 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 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 effective 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.
• 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-NFPA and
SM428A-NFPA are economical, low wattage, directional light
assemblies that are designed for use in a flashing mode. Lens
colors available are: amber (standard), red, blue, green, and clear.
These models provide three distinctive and prioritized
lighting patterns. The highest priority pattern is the left arrow
and right arrow directional signal. When this signal is selected,
the lamps are individually illuminated in a sequential sweeping
motion until all eight lamps are illuminated. The lower priority
pattern is the warn signal. When this signal is selected, an
alternating flash of the four outside lamps with the two inside
lamps occurs. This signal may be used when a directional signal is
not appropriate. The lowest priority pattern is the low power warn
signal. When this signal is selected, the two outside lamps on each
side of the light assembly will alternately flash.
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.
Low Power 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'
WARNING
These lights are intended for secondary warning only.
They are not intended for use as a primary warning
system.
III. INSTALLATION.
CAUTION
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 instruc-
tions packed with the mounting kit.
B. Control Head.
WARNING
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 effective-
ness 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:

OFF
ON HAZARD
FEDERAL SIGNAL CORPORATION
290A3618
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.
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.
WARNING
Failure to observe this WARNING may result in fire,
burns or blindness.
If shorted to vehicle frame, high current conductors can
cause hazardous sparks resulting 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 battery until ALL
other electrical connections are made and mounting of all
components is complete.
Verify that no short circuits exist, before connecting 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
location.
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. Illuminated Power Switch.
CAUTION
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 chassis 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. Low Power Warn Connections.
a. Connect one end of a user-supplied 22 gauge
wire to the vehicle parking brake switch so that + battery voltage
is supplied when the vehicle ignition switch is on and the parking
brake is applied.
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
290A3619
WHITE
SWITCH BRACKET
REAR VIEW
JUMPER WIRE FROM
INSTALLATION KIT
GREEN
BROWN
RED GOLD
TERMINAL
OFF-ON
SWITCH
CHASSIS GROUND
HAZARD
SWITCH
3
2
1
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.
CONNECT TO VEHICLE
PARKING BRAKE SWITCH
Figure 2.
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b. Connect the other end of the user-supplied 22
gauge wire to the control cable’s brown wire at the control head as
shown in figure 2. Use an insulated connector for this connection.
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 (+) positive
terminal of the battery using an in-line, user-supplied fuseholder
and 25A fuse. 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 signal. 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.
• At the start of your shift, you should ensure that the
light is securely attached and all lamps are operat-
ing properly.
• If a selected function does not perform properly 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 passengers, or
to others.
RETAIN AND REFER TO THIS MESSAGE
A. On/Off Switch.
1. OFF Position.
The SignalMaster is available for the low power
warn signal if the vehicle ignition switch is on and the vehicle
parking brake is applied.
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 operate as
selected by the Hazard Rocker Switch.
B. Hazard Rocker Switch.
NOTE
These patterns will override the low power warn signal.
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. Low Power Warn.
This pattern alternately flashes both end lamps on each
side of the light assembly.
To activate the low power warn pattern, the vehicle
ignition switch must be “on”, the SignalMaster’s on/off switch must
be “off”, and the vehicle parking brake must be applied.
CAUTION
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.
WARNING
Crazing (cracking) of lenses will cause reduced effective-
ness of the light. Do not use cleaning agents (which will
cause crazing) such as strong detergents, 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.
B. Lamp Replacement.
CAUTION
Use of higher wattage lamps can result in damage to the
colored lenses.
1. See figure 3. Remove and retain the two screws
which secure the lens. Carefully pull the lens straight away from
the light assembly.
-3-

290A3620
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 3.
CAUTION
Service life of lamp will be shortened if glass is touched.
If glass has been handled, clean with a grease solvent.
WARNING
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. 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.
CAUTION
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 7011163-04
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
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