Federal Signal Corporation SIGNALMASTER SM518A User manual

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
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.

CONTROL CABLE
YELLOW
BLUE
CABLE TO LAMPS
BLACK
290A2886B
TURN SIGNAL RIGHT
TURN SIGNAL LEFT
H1 H2 H4 H5
H3
RED RED +12V
RED +12V
(OPTIONAL)
(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
Copyright 2007 Federal Signal Corporation
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.