Command Light Knight Series Manual 

As a company, we are dedicated to producing the very best and most versatile flood lighting package available. We take great pride in the quality of our work and hope that you will find many years of satisfaction from the use of this equipment. Should you have any problems with your product please do not hesitate to contact us. COMMAND LIGHT_ 3842 Redman Drive Fort Collins, CO 80524 PHONE: 1-800-797-7974 FAX: 1-970-297-7099 WEB: www.CommandLight.com

LIGHT KNIGHT2. Save this guide for future reference. Contents Breakage or Damage During Shipment ........................................................................ Error! Bookmark not defined. Product Safety Precautions .......................................................................................................................................... 7 General Description and Specifications ...................................................................................................................... 7 Operation ....................................................................................................................................................................... 8 Raising the light from the nested position .................................................................................................................. 9 Returning the light to the nested position ................................................................................................................. 10 Installation ................................................................................................................................................................... 10 Installation Kit .......................................................................................................................................................... 10 Tools Required ......................................................................................................................................................... 11 Installation Notes ...................................................................................................................................................... 11 Location Requirements ............................................................................................................................................. 12 Mounting .................................................................................................................................................................. 13 Holster Mounting ..................................................................................................................................................... 13 Electrical Wiring ......................................................................................................................................................... 14 12 VDC ..................................................................................................................................................................... 14 Holster Wiring .......................................................................................................................................................... 14 Warning Device Wiring ........................................................................................................................................... 15 Maintenance ................................................................................................................................................................ 16 Cleaning .................................................................................................................................................................... 16 Center Switch Adjustment ........................................................................................................................................ 16 Power Failure .............................................................................................................................................................. 17 Rotate to center ......................................................................................................................................................... 17 Retract the lower stage ............................................................................................................................................. 17 Retract the upper stage. ............................................................................................................................................ 18 Troubleshooting .......................................................................................................................................................... 19 Technical Specifications – Standard DC Models (415D) ........................................................................................ 21 Specifications ............................................................................................................................................................... 22 Parts Lists - Exploded Views ..................................................................................................................................... 23 Exploded View (Lower Stage) ................................................................................................................................. 24 Exploded View (Midplate) ....................................................................................................................................... 26 Exploded View (Lamp Tree) .................................................................................................................................... 28 Wiring Schematics ...................................................................................................................................................... 30 Holster Box ............................................................................................................................................................... 31 Midplate .................................................................................................................................................................... 34 Lamp Tree ................................................................................................................................................................ 36

FAX: 1-970-297-7099 Fort Collins, CO 80524 WEB: www.CommandLight.com LIMITED WARRANTY Five Year COMMAND LIGHT warrants that the equipment is free from defects in materials and workmanship when used and operated for a period of five years. The responsibility of COMMAND LIGHT under this limited warranty is limited to the repair and replacement of any parts found defective. Parts must be returned to COMMAND LIGHT at 3842 Redman Drive, Ft Collins, Colorado 80524 with transportation charges prepaid (C.O.D. shipments will not be accepted). Prior to returning defective parts to COMMAND LIGHT, the original purchaser shall make a claim in writing to COMMAND LIGHT at the above address indicating the model number, serial number and type of defect. No parts or equipment will be received by COMMAND LIGHT for repair or replacement under this warranty without specific written authority from it in advance. Any parts damaged by improper installation, overloading, abuse or accident of any type or cause are not covered by this warranty. All equipment manufactured by us is tested before leaving our plant, and is shipped in good working order and condition. We therefore extend to the original purchasers the following Limited Warranty for the period of five years from the original date of purchase: 1. This warranty does not apply to defects caused by accident, misuse, neglect, or wear and tear, nor can we be held responsible for incidental and consequential expense and loss, nor does this warranty apply to equipment where alterations have been executed without our knowledge or consent. These conditions are readily discernible when the equipment is returned to us for inspection. 2. On all component parts not manufactured by COMMAND LIGHT, their warranty is to the extent that the manufacturer of such component warrants them to COMMAND LIGHT, if at all. Look in your local business telephone directory for the nearest repair station for the brand of parts you have or write to us for the address. 3. If equipment received has been damaged in transit, a claim should be made against the carrier within three days, as we assume no responsibility for such damage. 4. Any service other than our Authorized Service voids this warranty. 5. This warranty is in lieu of and is intended to exclude all other warranties, express or implied, oral or written, including any warranties of MERCHANTIBILITY or FITNESS for a particular purpose. 6. Travel time paid at a maximum of 50% and only if pre-approved.

and workmanship when used and operated for a period of five years. If during this time period, you have any malfunctions not related to misuse, accident, neglect, or normal wear and tear, please take the following steps in order to have your light tower serviced under COMMAND LIGHT’s warranty. 1. Contact us immediately for initial diagnosis and parts if needed at 800-797-7974 or [email protected] 2. You will need to have immediate access to light tower. This process can be done by individuals with little mechanical ability. (Involves pushing buttons and telling us what the light tower is doing or not doing) 3. We then send parts (if needed) and have a technician dispatched (if needed) with a written work authorization number and a base amount of hours allotted to do repair 4. We remain available for service support via phone, email, or video conference while technician completes repair, also to extend original time allotted if additional issue arise 5. Mark repair as completed and validate the work authorization number for hours of labor / travel rates as agreed during diagnosis 6. Finally, we will pay out or credit the invoice when we receive it from person/company performing the repair Please make contact with us as soon as problems arise in order to execute our warranty. We must have knowledge of the issue and a work order in place in order to pay or reimburse the department with the issue. Any unauthorized service voids this warranty. (No work is authorized until the call is made to us) Contact Us Early – before any work is done – We’d love to help! *excludes light producing components (bulbs, lasers, LEDs) These components come with their own manufacturer warranty. Contact us and we can help get it. Breakage or Damage During Shipment The transportation company is fully responsible for all shipping damage and will resolve problems promptly if you handle it correctly. Please read these instructions carefully. Examine the contents of all shipping cases. If you find any damage, call your transportation agent at once and have them make a description on the freight or express bill describing the damage and the number of pieces. Then contact us and we will send you the original bill of lading. Also promptly contact the transportation company and follow their procedure for filing a claim. Each company will have a unique procedure to follow. Please note, we cannot and will not enter claims for damages. If we filed claim here, it would be sent to your local freight agent for verification and investigation. This time can be saved by you filing the claim directly. Every consignee is on the ground floor, in contact with the local agent who inspects the damaged goods, and thus, each claim can be given individual attention. Since our goods are packed to comply with the regulations of all railroad, truck, and express companies, we cannot allow deduction from any invoice because of any damage, however, be sure to file your claim promptly. Our goods are sold F.O.B. factory. We take receipt from the transportation company certifying that the goods were delivered to them in good order and our responsibility ceases. It is seldom that any breakage or damage occurs in any of our shipments and in no case will the customer be out any expense if they follow the above instructions. Be sure to keep all damaged goods subject to examination of the truck or express company inspector, who may call on you some time later. These damaged goods, of course, will belong to them, and they will inform you what to do with them. If you dispose of these damaged goods, your claim may not be paid.

X Never operate the COMMAND LIGHT KNIGHT2 near overhead high voltage power lines. The COMMAND LIGHT KNIGHT2 is manufactured from electrically conductive materials. X Do not use the COMMAND LIGHT KNIGHT2 for uses other than its intended purpose. X Do not move emergency vehicle with the light extended. Visually verify that the light is completely nested before moving vehicle. X Do not change light position while people are located within its operating envelope. There are numerous pinch points that can cause serious bodily injury. X Do not use a high-pressure washer or subject the light to high volumes of water when cleaning. X Never use the COMMAND LIGHT KNIGHT2 as a lifting device or mobile arm. X Do not use a COMMAND LIGHT KNIGHT2 that has been damaged or is not fully functional, including non-working indicator lamps. X Never hold any part of the COMMAND LIGHT KNIGHT2with a hand or foot while it is in motion. X The COMMAND LIGHT KNIGHT2 has numerous pinch points. Keep loose clothing, hands and feet clear of moving parts.

The KNIGHT2 is designed to provide high intensity emergency scene lighting with quick precision. As with any electromechanical device, take precautionary steps to ensure safe operation. Never operate the KNIGHT2 near overhead power lines. There are several standard lighting options available for the KNIGHT2. The emergency vehicle generator provides power for the 12 VDC circuitry. The umbilical corded control unit is powered via 12 VDC eliminating hazardous voltage levels within the hand held control box. The KNIGHT2 is manufactured to provide years of service with a minimum of maintenance. Model # Description Minimum Power Requirements KL415D 4 x LED 100 Amps, 12 VDC

Using the control box, raise the lower or upper stage. You may also activate both stages simultaneously. Control switches are of momentary action style and must be held in the “on” position to actuate the stages. The KNIGHT2 has an override system that precludes rotation of the upper stage until the lower stage has elevated approximately 16” from the nested position. When the lower stage is below 16” the following conditions exist: • Upper stage is prevented from rotating. • All lights are turned off, including strobe light if equipped, regardless of light switch positions. • Prevents the upper stage from moving down if upper stage is not centered. If the supply from the generator is marginal, position the KNIGHT2 before turning on lights.

The KNIGHT2 is equipped with an Autopark function as a standard feature. The green button on the control box initiates the Autopark sequence. Once initiated, the “Emergency Stop” red button indicator is illuminated. Pressing the “Emergency Stop” button will cancel the Autopark sequence. Autopark Sequence Press green button on the controller once. It does not need to be held in position. The Autopark sequence begins: 1. “Emergency Stop” light is illuminated. 2. Lamps are extinguished. 3. Upper stage begins rotation to the center position. If equipped with back light option, back light begins rotation and returns to the home position. 4. Once upper stage is centered, rotation stops, lower stage begins retracting. 5. After lower stage has fully retracted, upper stage begins retracting. Upon upper stage retracting fully, “Emergency Stop” light turns off. Installation The KNIGHT2 must be installed by a designated installation facility by qualified personnel only. All safety precautions must be thoroughly understood before installation. Please consult the factory for additional installation information assistance. Installation Kit Included with the KNIGHT2 is an installation kit. Verify that the kit contains the following items: (1) 50 feet of 2GA-2 Conductor power cable (1) 50 feet of 22GA-20 conductor cable (1) Pre-wired HOLSTER BOX w/cover (1) Handheld Controller (1) Small hardware parts bag with: (4) mounting spacers (4) 5⁄16-18 x 2 ½” bolts (4) 5⁄16-18 nylon lock nuts (8) 5⁄16” flat washers (4) large diameter flat washers (2) ¼-20 x 5⁄8” Phillips pan head machine screws (4) ¼” flat washers (2) ¼-20 nylon lock nuts (3) ½” 90° sealing connector w/nut

Sling for lifting Drill 21/64”, 17/64” drill bits Hole punch for metal with 7/8” and 15/16” diameter capacity Phillips head screwdriver, #2 Command Light flat blade screwdriver (included with light) 7/16” and 1/2” combination wrenches and/or ratchet and 7/16” and 1/2” sockets 8” adjustable wrench Tongue and Groove Pliers Wire stripper or razor blade knife Solder-less wire connector crimp tool Silicone based gasket sealer, RTV™ recommended Installation Notes The KNIGHT2 weighs approximately 150 pounds. Use mechanical assistance to lift the light into installation position such as a forklift or crane. Use the provided fender washers under the mounting surface to distribute the weight load evenly. When routing the connecting electrical wires take care to avoid sharp bends, hot components or other hazards to the wire. The KNIGHT2 is not designed to be operated in a raised position while the vehicle is in motion. The KNIGHT2 includes warning circuit wiring to enable a warning device.

The surface should be flat or have only a slight crown. For a recessed installation allow for a minimum of 58” x 29”. Consult with factory before construction of recessed installation. Verify all dimensions before installation to ensure proper operation of light will not infringe on other installed components. For all other installations refer to the dimensional drawing included in the back of this guide that represents your particular model of light. The drawings reflect the dimensions of the “working envelope” of a typical light tower. Make certain sufficient clearances are incorporated in your installation to allow for variations (vehicle body flex, environmental conditions, future servicing needs, etc.) If your light is not represented, call the factory prior to beginning any construction of a recessed installation. Four mounting bolt holes are required. Additional holes may be drilled in the frame ends if necessary to clear obstructions. Access holes for the power cord cabling should be in close proximity to the relay box access holes on the light. Installing the cords with a sweeping 90° or 180° bend will provide better results. The control box holster should be mounted in an area shielded from the weather. Allow a minimum of 10” clearance above the control box holster mounting location for easy access to the controller.

modified to conform to the contour of the mounting location. Remove any obstructions below the mounting surface such as headliners. Attach any necessary lifting attachments to the KNIGHT2. The center of gravity (balance point) is slightly behind the lower bank of lights. Slowly lift the KNIGHT2 and check for balanced lifting. Lower and make any necessary adjustments to the lift points. Lift and place the KNIGHT2 into position above the spacers. Before placing the full weight of the unit on the spacers align spacers with the holes in the end frame castings. Drill 21/64” holes in the mounting surface using the end casting holes as a template. Fasten the light using the provided hardware. To ensure a weather-tight installation apply a thin bead of silicone based gasket sealer to the base of the spacer and underside of bolt head. Remove any lifting straps and devices from the KNIGHT2. Locate and drill the wire feed holes. Holster Mounting Using the holster mount as a template, mark hole locations. Drill 17/64” mounting holes. Drill any holes required to route the control cable from the holster to the KNIGHT2 relay box. Attach the holster to the holster mount with the provided hardware.

Run the control wire from the control box holster to the KNIGHT2. Run the power wire from the breaker box or generator to the KNIGHT2. A 100 Amp breaker is recommended on DC models. Make the control connections in the KNIGHT2 relay box. The Model KL415D series KNIGHT2 comes pre-wired to connect to 12 VDC. 12 VDC Holster Wiring Determine if an elevated warning device will be used in conjunction with the light tower. If a warning device will be used, use the wiring diagram on the next page, otherwise, use the wiring diagram in the back of the user guide. After routing the control cable into the holster through the sealing connector, attach individual wires to the provided connectors and insert the connectors into the proper ports on the circuit board

Tools Required: • 3/32” Flathead Screwdriver • Wire Strippers • Small Torch or Lighter Wire the gray 22-20 control cable wires to the small connectors using the wiring schematics provided. There are 2 different schematics, one is the standard version and the other is the version for dual control with wireless controllers or V-Mux control. The standard schematic will be used for V-Mux or any other multiplex system if it is only being used for elevated warning. A V-Mux wiring schematic and circuit board troubleshooting guide are included. Detaching & Attaching the Controller 1. Loosen the small nut. Make sure the tab on the ethernet (CAT 5) connector is in the slot before attaching the cord. Lock the large nut, make sure the ethernet cord is pushed all the way in, lastly tighten the small nut onto the cord. 3.Gently slide the connector away from the holster. 4.Disconnect the cable by pressing down on the tab and pulling. 2.Loosen the large nut.

fasteners. To further enhance corrosion resistance all exposed surfaces receive a powder coated paint finish. To ensure years of trouble free service periodically clean all external surfaces with a mild detergent solution and a gentle spray of water. DO NOT USE A HIGH-PRESSURE WASHER, which will force water into sensitive electric circuitry. Lamp lenses may be cleaned with any commercially available glass cleaner. Upper and lower stage actuators are sealed units and do not require adjustment or lubrication. The actuators have slip-clutches to compensate for minor stroke tolerances at the limits of its travel as well as internal limit switches. The actuator may produce a ratcheting sound at each end of the stroke which is normal. The actuators should not be made to ratchet excessively, this can lead to premature actuator clutch failure. All pivot points on the KNIGHT2 are self-lubricating thermal polymer. Periodic cleaning with a moisture displacing cleaner and soft bristle brush, without disassembly, to remove accumulated dirt and debris will minimize wear. Center Switch Adjustment 1. From a nested position, raise the lower section of the KNIGHT2 until there is room to access the center switch on the bottom of the midplate. 2. Verify to see that the centering cam attached to the spindle is activating the center switch. 3. Loosen the single screw holding the pointed centering cam in place. 4. Slide the centering cam so its point is directly against the center switch and ensure there is some play in the center switch arm. Without this play, the switch could be crushed or damaged during rotation. 5. Slide the cam in the counter-clockwise direction when viewing from below until the centering cam does not engage the center switch. 6. By watching the center indicator light (green light on the holster), slowly move the centering cam in the clockwise direction when viewed from below until the center indicator light activates. You might also hear a soft click in the center switch when activated. 7. Once the cam is at the point where it starts activating the center switch, hold the centering cam in place and tighten the mounting screw. 8. Rotate off center and activate the Auto Park sequence. Watch where the angled point of the lamp tree aligns with the main lift arm when the lower stage lowers. 9. If the center switch is adjusted properly, the lamp tree will come down slightly off center. As the angled point of the lamp tree lowers into the lift arm, the centering cam will be rotated more fully onto the center switch. This will ensure the center switch is fully activated in the nested position 10. If problems adjusting center still persist you may need to adjust the center switch bracket, or call Command Light for technical assistance at 1-800-797-7974.

temporary, reestablishing power may be easier than manually retracting the light. Note: Disconnect power source from the KNIGHT2 before manual operation. Rotate to center Locate the belly plate on the bottom of the lift arm and remove it by loosening all 4 screws and only removing 2 of them. Disconnect the Red/White and Brown wires from one side of the connecting terminals using a small flat blade screw driver. Slowly apply pressure to the lamp tree to manually rotate to the centered position. Trying to rotate too quickly or with too much pressure can break the rotation motor shaft. Be certain that you rotate in the proper direction; the upper stage can rotate a full 360˚. Generally, you need to rotate the lamp tree in the direction that requires the least amount of travel in order to reach a centered position. If manual rotation causes the rotation belt to slip, this is alright if minimized. Excessive slippage on the belt may cause enough damage for the need of belt replacement. Retract the lower stage Slowly apply pressure to the rotation platform to manually rotate to the centered position. Trying to rotate the platform too quickly or with too much pressure can break the rotation motor shaft or cause the toothed drive belt to shear a tooth. The upper stage can be rotated in either direction. Generally, you need to rotate the platform in the direction that requires the least amount of travel in order to center the platform. Support the mid-plate assembly with temporary blocking to relieve the tension on the lower actuator pivot pins. Using a small flat blade screw driver, remove the retaining rings that secure the lower pivot pin in place. New retaining rings must be installed before returning light to service. Use a brass drift punch to remove the pivot pin from the extension end of the actuator. Avoid using a hardened steel punch which could peen the end of the shaft thus damaging the bore within the aluminum pivot blocks.

pressure on the main lift arm to remove support blocking then slowly lower the lift arm allowing the actuator shaft to extend past the lower pivot blocks. Retract the upper stage. Support the lamp tree with temporary blocking to relieve the tension on the upper actuator pivot pins. Disconnect the two actuator wires from the connecting blocks located near the bottom bank of lights. The actuator wires are Green/Black and Green/White. Using a small flat blade screw driver remove the 4 e-clips securing the lower pin of the upper actuator. While supporting the lamp tree, lamp tree weighs between 27 – 46 pounds depending on configuration, use a brass drift to remove the pin. Lift up on lamp tree to remove support blocking. Rotate the actuator towards the front of the light. The upper stage will not be completely lowered but should provide ample clearance to transport the light. Cushion and secure the actuators and other components as necessary before transporting.

No power to the unit Check power input connections. Incorrect installation Refer to installation instructions. Upper stage will not rotate Lower stage not raised above safety limit (16” above base) Raise lower stage higher. Rotation motor failure. Consult with factory. Lights will not illuminate. Lower stage not raised above safety limit (16” above base) Raise lower stage higher. Circuit breaker tripped. Check circuit breaker at power supply. No power to the unit. Check power supply operation/output. Lamp filament broken. Replace lamp. Rotation coasts after switch is released Rotation belt is loose. Adjust belt to provide no more than ¼” slack Unit will not nest Upper stage not centered. Raise lower stage higher than 16”. Center upper stage (green light illuminated) Unit being operated on a slope >15°. Lower lamp tree to horizontal. Using a pike pole, hold unit level while lowering to nest position. Autopark button must be held in to park unit Faulty or stuck nest switch. Check nest switch ground and operation. Rubber boot may have shrunk and is holding in switch. Water in electronics. Remove moisture from ground points and electronics. Do not use a pressure washer to clean unit. Upper Actuator & Rotation start at the same time Down limit switch stuck or damaged. Aluminum plunger which activates down limit switch should move freely. Verify proper switch operation. Wires on back light catching Check for 90 degree sealing connector on lamp tree. Contact factory for replacement part. No lights or rotation Check safety limit sensor, bad, etc. Contact factory for replacement part. Autopark is off Center Center switch out of alignment. Refer to instructions on page 18. Popping noise during Back Light Rotation Switch boots stuck, faulty rotation relay. Replace switch boots. Contact factory for replacements parts.

Dimensions (with strobe and ½” mounting spacers) – May vary by model: Height(Depth) Length Width Retracted 14” 47” 36” Extended 84” 52” 36” Recessed installation 14” 58” 42” Minimum Weight: 136 pounds Wiring: Main Power VDC 2/2 SO cord 50’ provided Control wiring 22/20 PVC Jacketed 50’ provided Relay protection: Lights Cole-Hersey 3055 100 amps Other electrical Cole-Hersey 3055 40 amp Current Draw / Power Requirements: Average Generator Requirement 150 Watt LED 12 VDC/80 amps 1 kW minimum 220 Watt LED 12 VDC/100 amps 1.5 kW minimum Lift actuators and rotation motor will cause higher current draw during use. Motor Duty Cycle: (All motors thermally protected, specifications are to thermal relay trip): Lower stage 1:3 (90 seconds maximum per 5 minute) Upper stage 1:3 (90 seconds maximum per 5 minute) Rotation 5-6 Revolutions Motor Speed: Lower stage 1.0 inches per minute 12 seconds to full extension Upper stage 0.5 inches per minute 12 seconds to full extension Rotation 2.75 RPM at lamp tree Operation: Angle of vehicle 15˚ maximum incline Wind load: Design maximum 60 mph Maximum tested 55 mph