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1. eet a SRS Susa 24 0 25 10 TROUBLESHOOTING veci 0101010101010101 o dnte ceo Dd 26 Pp 1 1 1 1 ER 26 IND TOP APEC L 0 21 SENSOR WE CHRO UID i SOO TIN cts eS ef eM maa 28 LI TECHNICAISPECIEICATIONJS Z 0 0101010101010101 debo e ecu D a ipu Dee voe asa 29 CEST 502252 um Huc 29 0 31 l LO eR buy AIME 33 xcu x 35 37 001010101010101 12 PamgIS ISTI KL450STIANDARD ASSEMBI XY ha aaa esed ed ot os 37 EE BOT TT Soi 1 1 1 1 1 1 1 000 41 43 0000 O 44 BACKLIGHT OPTION PARTS LIST SEE FIGURE 5 0 000101 45 METAL HALIDE OPTION LAMP TREE PARTS LIST SEE FIGURE 6 1 10 202024 2 20 sese as sese ee enar enean 46 METAL HALIDE OPTION TRANSFORMER COMPARTMENT PARTS LIST SEE 7 0 4004000000 00 47 DESCRIPTION c2. 12VDC FROM VEHICLE FOR A DEVICE THAT REQUIRES GROUND TO ACTIVATE D 6 me 0707 1 OF O BLACK 7 MIYELLOW ORANGE E WARNING 12VDC FROM VEHICLE NT 12VDC FROM VEHICLE 8 Viaintenance Lamp Replacement WARNING NEVER remove any lamp from it s socket while power supply is engaged Allow sufficient time for the lamps to cool The surrounding metal lamp housings can cause serious burns Tools required Clean oil free cloth Cleaning alcohol Protective gloves Position lamp tree so lamps are readily accessible This 15 usually with the lower stage in the retracted position and the upper stage extended to 90 2 High voltages can be present inside lamp housings Disconnect the power supply from the KNIGHT The glass capsules of lamps that have been in service tend to be brittle handle them with caution 435 KL450 Grasp the lamp lens bezel firmly release the latch that holds the lamp bezel in place Use caution The lamp bezel and lens may fall 1f not properly grasped KL450 models after serial number KL4590 have a screw instead of a latch Caution be certain that the lamp 1s cool to the touch before handling Do not touch the lamp directly Use a clean oil free towel to handle the lamp The lamps operate at high temperatures Han
3. 47 AERIAL OPTION LAMP TREE PARTS LIST SEE FIGURE 8 6 6 6666 06 00 48 KL475 490 OPTION LAMP TREE PARTS LIST SEE FIGURE 8 02000000 0060 000000000 49 IS CONTROL WIRING SC HENFATICS n 10 7 7 0010101010101 50 CONTROL CORD Ros oet ems operati uqa apa 50 COILED CORD uya ayayasqa Da n Seeks e soin ee 51 52 07 53 00000000 000 54 EURO 55 juive O VOLT O A 0 56 I4 EIMETED WARRANTY 0 57 Thank you for Investing a Command Light product In order to serve you better when contacting Command Light for assistance please have the serial number s available The serial number can be located stamped into the frame in proximity to the power connection entrance Please refer to the figure below Later model Knight Lights have an identification plate af
4. 10 LOCATION REQUIRE NIN Dv Luka amu SES muon 11 000031 12 28 11 D PLEBISCITO 12 CONTROLBOX BOESPERAMIOUNTING esee bd obe to puq en Rd etie 12 ELECTRICAL WIRING u u lt k w fer de ee de d UT 13 I20 AIC WARING 14 DAE VAC WIRING DIAGRAM TS E ESD Dra ans 14 220 V AC 0 UE ahay 15 MAC O DT NTC kus bu 000 15 7 WARNING DEVICE INSTALLATION 01010101010101 16 MAINTENANCE i 010101010101021 11 17 uuu 17 1 00000 17 0 1 1 1 1 1 1 1 1 unai 2 17 Kg Out tectis M Ln ME 18 Nu d UA as 18 CENTERS WITCH TNE uu u 000 19 ROTATION DRIVE BELT ADIUSTMEN u his 20 ROTATION DRIVE EPL ACE MENT ua k m Q a at tees 21 EM POWEREALEURP i Q HT 24 RETRACT THE LOWER
5. 25252555252 5 E 1 4 9 85 _ w w 10 ET wow 5220 s 10 0006 67076707676 i O te 22532 AUTO PARK AUTO PARK EMERGENCY STOP CIRCUIT EMERGENCY STOP 20 CONDUCTOR 52 KL470MH gt LIGHT RIGHT Jew LIGHT 42 RIGHT nlla cili EIE P EE elelelelele 4 elll ka bul a hu ba ba LITT mu 3 ak LEFT TU LIGHT 1 LEFT T 1 AIFEEDEUE gt 0 1 i i i 2 4 8 1 E Li ds L 1 1 ma 1 1 3 s 1 E ERR w 8 eee ae ld Baka x f 52525554 LL A T 0 z C Le oo y 5254 C ete uta ne oe nts 14 kuku ata at 5254 tee Lj Dx SERERE qub E Tr i d EE 5 5 5 e c 53 KL490 LJ E 9747476787470
6. s a BLACK BLACK 120VAC oe TAST RED 120VAC 240VAC IF USING 240VAC SUPPLY m SUPPLY REMOVE RED JUMPER WIRE NOTE The load on the 2 power legs will not be equally balanced The RED lead powers the lamps and will carry 3395 more load The BLACK lead supplies voltage for rotation and actuation 14 220 VAC European GROUND NEUTRAL 220 VAC LINE IN FROM POWER SOURCE Verify that there 15 sufficient overhead room available and test operation of the light 220 VAC 12 VDC European H 3 GROUND O 7 0 NEUTRAL 220 LINE O LL lt 12 VDC Verlfy that there 15 sufficient overhead room avallable and test operation of the light 15 7 Warning Device Installation 2 The KNIGHT nest sensor can be used to activate a warning device when light 15 extended Typically the vehicle will have a light or buzzer that actuates when compartment doors are open To connect such a device determine whether it 1s activated when it receives 12 VDC or when it receives a path to ground The connector for hooking up a warning device 1s located in the holster box that holds the control unit FOR A DEVICE THAT REQUIRES 12VDC SIGNAL TO ACTIVATE CL IO eo 9 C CU YELLOW WARNING DEVICE GROUND
7. 211 5 153 42 Controller Parts See Figure 3 065 1284 065 1284 5 WITCH DPMT ROTATION 5 065 12845 5 6 065 12856 1 SEALCON NUT 69 I0 COILED UMBILICAL CORD Figure 3 065 12842 3 1 5 6 7 8 EN Lj l 2 C4 065 2846 7 BOOT SWITCH COVER NAM NEN LJ Ld 1 1 1 3 1 7 1 1 1 1 1 1 1 0 CAUTION BE ALERT TO ELECTRICAL HAZARDS 43 Holster Parts See Figure 4 6 X SM SCREW 4 40 PH PHILIPS SS 6 X SM SCREW NUT SEALCON SEALCON STRAIGHT 8 32 X PH PHILIPS CS 55 Backlight Option Parts List See Figure 5 DESCRIPTION TREE BACKLIGHT KV2 WELDMENT MOUNT LAMP BACKLIGHT KV2 PULLEY 48 GR 3MM P 3125 ID BELT 11 GR 3MM P 333 NUT 10 32 HEX SS 6 065 1384 1 GEAR MOTOR BACKLIGHT 21 005 SHAFT BACKLIGHT KNIGHT V2 8 075 12050 2 KEY SHAFT BACKLIGHT 9 075 12030 1 TRIGGER SWITCH BACKLIGHT BLOCK SHAFT BACKLIGHT SPACER SHAFT BACKLIGHT NUT 4 20 HEX NYLOCK SS MOUNT MOTOR BACKLIGHT KV2 WASHER FLAT 4 SS WASHER SPLIT LOCK SS BOLT 20 HEX SS SWITCH LIMIT BACKLIGHT BOOT SWITCH GRAY RELAY LATCHING AUTOPARK Figure 5 45 Metal Halide Option Lamp Tree Parts List
8. aa TA t t t s 52506 LAMP TREE HARNESS EEE gt odd e Lu x Ew x aa SC a 1 IHOIDIOVB k L 1 5 0 LEM 625000650504 48 TT TAT TTT TIT h OR e ke de Tf 54 SS3NSYH 555 d MO MO XS AG 5 2o Melt obit 1 1 B pom 006 S00Z rZ S l LIND 015 015 i E 1d EEE e we A LE 5 E IR E 5256 ERRASSE cone SSJ3NMVH 2V s SOE ECCE S SES Sr i a i uu dOIS A2N3243W3 2015 t a a et e SRS LAMP TREE HARNESS E utat 1 T p Tp Tp T W 98 80 595095660506
9. 240 VAC Generator Requirement 500 Watt bulbs 24 amps 12 amps 4 kW minimum 350 Watt bulbs 17 amps 9 amps 2 kW minimum 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 0 5 inches per minute 10 seconds to full extension Upper stage 0 5 inches per minute 12 seconds to full extension Rotation 3 25 RPM at lamp tree Full Deployment Lower and upper stages 15 seconds to full actuator extension Auto Park Rotate 180 degees and 40 seconds from full extension retract Operation Angle of vehicle 15 maximum incline Wind load Design maximum 65 mph Maximum tested 55 mph TU 0 COMMAND LIGHT lt KNIGHT MODEL 435 2100 WATTS 120 9 AMPS MODEL 450 3000 WATTS 120 12 AMPS 874 22231 WEIGHT 136 LBS 62 Kg E 31 861 RECOMMENDED AREA FOR CORD or MINIMUM CLEARANCES FOR CONTROL amp HOLSTER INSTALLATION 1 f 54 1421 Em 5 1271 4 1143 124 3161 9 E 18 4561 144 370 30 KL470MH Dimensions Height Depth Length Width Retracted 14 75 47 27 Extended TA 52 27 Recessed installation 10 Maximum 54 Minimum 30 Minimum Weight 160 pounds Wiring 110 VAC 10 4 SO cord 50 provided Control wiring 22 20 PVC Jacketed
10. The connector 1s located above and in front of the actuator The actuator connector Is the medium sized of the 3 connectors found there 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 Remove retaining rings from lower pivot 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 10 Troubleshooting General Possible Cause Unit will not extend No power to the unit Check power input connections Incorrect installation Refer to installation Instructions rotate above 40mm Allow rotation motor to cool thermal overload Rotation motor failure Consult with factory Lights will not Lower stage not raised Raise lower stage higher illuminate above 40mm switch 15 released light illuminated Unit being operated Lower upper stage to horizontal Using a pole hold slope gt 15 degrees unit level while lowering to nest position 26 Autopark Malfunction Possible Cause be held in to park unit ground Do not use a pressure washer to clean unit Stuck or broken nest Clean sw
11. i 5 m ata STROBE HARN a o d m TELE 218 801204802 02 003 022 2 4 ONVAWDJ EURO 220 Volt OO 5255504 IHANIN 595594 1 es Sd 2522506 t M 1 QUOC ONU LOMO 015 WHYd OLnV MMvd oLnv dOIS w aa m ah l t alata 2 LAMP TREE HARNESS s gs meo iid Euro 220 Volt 12VDC 14 Limited Warranty Five Year COMMAND LIGHT warrants that the equipment 15 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 15 limited to the repair and replacement of any parts found defective Parts are returned to COMMAND LIGHT at 1303 East 11th Street Loveland Colorado 80537 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 b
12. 50 provided Relay protection Lights Cole Hersey 3055 40 Other electrical Cole Hersey 3055 40 Current Draw Power Requirements Max 110 VAC Max 240 VAC Generator Requirement 175 Watt bulbs 10 amps 7 amps 2 kW minimum 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 0 5 inches per minute 10 seconds to full extension Upper stage 0 5 inches per minute 12 seconds to full extension Rotation 3 25 RPM at lamp tree Full Deployment Lower and upper stages 15 seconds to full actuator extension Auto Park Rotate 180 degrees and 40 seconds from full extension retract Operation Angle of vehicle 15 maximum incline Wind load Design maximum 65 mph Maximum tested 55 mph 1 4 35 LM m 1 RECOMMENDED AREA FOR POWER CORD MOUNTING HOLE LOCATION 45 1143 32 MODEL 470MH 700 WATTS 4 175w AMPS WEIGHT 160 LBS 73 Kg MINIMUM CLEARANCES FOR CONTROL amp HOLSTER INSTALLATION FRONT VIE SIDE WIE ass 114 KL475 490 Dimensions Height Depth Length Width Retracted 13 375 54 75 30 Extended 95 25 30 Recessed installation 13 Maximum 58 Minimum 327 Minimum Weight 174 pounds Wiring 240 VAC 10 4 SO c
13. Parts Lists Parts List KL450 Standard Assembly See Figure 1 SCREW HEX HEAD 4 20 X 7 8 SS 6 12 06456 E CCLIP 02 8 1 075 01700 ARM STABILIZER 9 1 075 0600 SHAFT LOWER STABILIZER PIVOT WASHER INTERNAL LOCK SS SCREW PANHEAD MS 20 X SS SCREW PANHEAD PHILLIPS 4 40 X SS WASHERS INTERNAL LOCK 4 SS SCREW HEX HEAD 20 X 1 SS WASHER SPLIT RING LOCK SS 27 SCREW HEX HEAD 4 20 X 1 SS WASHER SPLIT RING LOCK SS SCREW PH MS 20 X 2 5 WASHER SPLIT RING LOCK SS SCREW HEX HEAD 4 20 X 1 SS WASHER SPLIT RING LOCK 44 SS 60 1 075 0410 DISK LOWER ROTATION x 66 1 065 0883 MOTOR ROTATION 68 1 07506400 KEY DRIVEPULLEY 69 4 0341103 NUT NYLOCK 4 20 SS SCREW PH MS 4 20 X 1 SS 80 2 034 3059 SCREW FHMS 832X5 88S Starting with Serial Number KL46380 _____ 1 03221087 BOLT HEAD 10 7 _____ 1 03 1080 NUT HEX 10 86 2 075 0610 GUIDE UPPER LAMP TREE WIRE 38 89 4 03 1103 WASHER SPLIT RING LOCK 5 16 SS __9_ 12 034 1033 NUT NYLOCK 20 SS SCREW MS 20 X 7 8 SS NUT 4 20 JAM SS BOLT HEX HEAD 4 20 X 1 SS NUT NYLOCK 20 SS 95 6 0915332 C 6 06 2800 BULB 500WATT 220 6 00 1404 BULB 350WATT 96 1 07599000 HARNESS
14. stage 15 not centered 2 If the supply from the generator is marginal position the KNIGHT before turning on lights Returning the light to the nested position 2 The KNIGHT 15 equipped with an auto park function as a standard feature The green button on control box initiates auto park sequence Once initiated the STOP red indicator button 15 illuminated Pressing the STOP button will cancel the auto park sequence Auto park Sequence Press green button labeled AUTOPARK once It does not need to be held in position The auto park sequence begins 1 Emergency STOP red light 15 illuminated 2 Lamps are extinguished 3 Upper stage begins rotation clockwise to the center position 4 Center switch cam on spindle contacts the center switch Green center indicator lamp 15 illuminated 5 Once upper stage 15 centered rotation stops lower stage begins retracting 6 Down limit plunger on midplate contacts plastic strike pad on frame engaging down limit switch 7 After lower stage has fully retracted upper stage begins retracting 8 Nest contact bolt contacts nest switch protective rubber cover on relay box 9 Upon upper stage retracting fully red emergency stop light turns off 5 Installation 2 The KNIGHT 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 ins
15. such as a forklift or crane Use a sling to grasp the light Use the provided fender washers inside the mounting surface to distribute the weight load evenly 10 When routing the connecting electrical wires take care to avoid sharp bends hot components or other hazards to wire 2 The KNIGHT 15 not designed to be operated in a raised position while the vehicle is In motion The 2 KNIGHT includes warning circuit wiring to enable a warning device letting the vehicle operator know 2 when the KNIGHT 15 not in the nested travel position Location Requirements 2 The KNIGHT can be mounted on any location that 1s KL435 KL450 47 x 23 KL470MH AT x 27 KL475 490 x 32 KL495A 56 x 23 The surface should be flat or have only a slight crown Recessed installations KL435 KL450 Allow for a minimum of 54 x 24 and a maximum of 10 deep to allow for proper operation KL470MH Allow for a minimum of 54 x 30 and a maximum of 10 deep to allow for proper operation KL475 490 Allow for a minimum of 58 x 32 and a maximum of 10 deep to allow for proper operation KL495A Allow for a minimum of 58 x 24 and a maximum of 10 deep to allow for proper operation Four mounting bolt holes are required Additional holes may be drilled in the frame COMMAND LIGHT KNIGHT ends if necessary to clear obstructions Access hole for the power cord cabline should be in close pro
16. COMMaND LIGHT 4 KNIGHT COMMAND LIGHT KL450 P O BOX 87 KL4 70NH LOVELAND CO 80539 KL475 PHONE 1 800 797 7974 KL490 FAX 1 970 667 4296 WEB www commandlight com KL495A Serial Numbers KL4901 and higher This document supersedes all previous documents Effective Wednesday January 04 2006 Please take the time to read this manual before installing or operating light Save this guide for future reference CONTENTS 1 BREAKAGE OR DAMAGE DURING SHIPMENI 4 1 BREAKAGE OR DAMAGE DURING SHIPMENI 5 2 GENERAL DESCRIPTION AND SPECIFICATIONS 6 FEATURE T gt PRODUGT SAFETY PRECAUTIONS 000101010101010 8 A SOP E RA TION S 001010101030111 9 RAISING THE LIGHT PROM THE NESTED POSITION 0 9 RETURNING THE LIGHT FO THE NESTED POSITION Sess u uuu ate set Suha SS 9 UTO 0 cee s m ELS UE 9 BINS PATA 0101010101 10 SSE E A A 10 amam am
17. K ORANGE BLACK BLUE BLACK LOWER MOODLE UPPER LICHTS LIGHTS BLACK WHITE RED WHITE GREEN WHITE BLUE WHITE TOWER E C BLUE TG DASH INDICATOR LIGHT FROM PIN 11 WHITE BLACK 50 Control Box Coiled Cord PIN 1 BLARE 1 LIGHTS 2 WHITE 5 5 c MIDDLE LIGHTS 4 GREEN 4 GROUND 5 ORANGE E T m 6 BLUE 7 CENTER INDICATOR RU E 8 151 STAGE UP 8 RED BLACK T x 9 GREEN BLACK 7 112 TOWER UP LIGHT 10 GRAY 11 PURPLE 12 YELLOW E 1 5 14 TAN BLACK 1 15 BROWN WHITE 2 RED 5 GREEN 4 ORANGE 5 BLUE amp WHITE BLACK 7 RED BLACK 8 GREEN BLACK 9 ORANGE BLACK 10 IDOLE UFPREF BLUE BLACK 11 LIGHTS LIGHTS BLACK WHITE 12 TO TOWER RED WHITE 13 GREEN WHITE 14 BLUE WHITE 15 BLUE UE TO DASH INDICATOR Ligh LIGHT FROM 11 CONTROL BOX 51 KL450 5506060 0 COO CX CX XXX X O9 XX XXX X X 36 XXX m Tete MASA T ta v AY XO OX 09 CX 6X 1 BR ere ee 59595060604 0596250606206260606060600620620606060606000660069506009 OOOO POR 2 em e 52 sl k WE sn 676767674 SAAN k 5
18. LAMP 98 2 0341102 20 55 gt 0 0 0 99 2 034 11028 WASHER SPLIT RING LOCK SS SCREW FLAT HEAD 4 20 X 1 SS SCREW PHP MS 2 20 X 1 SS WASHERS INTERNAL LOCK 1 4 SS NUT NYLOCK 4 20 SS 39 Figure 1 f 9 AV ig 4 2 oh SS 9 6 G K 2 gt 4 cef x d x T Relay Box Parts See Figure 2 0 0 0 41 a IE 15 HIATT w 035 MO is dO LPS cae eas 30915 271 a bas dr de do Ln 5 uaddn SE 398 ee da Le 35915 uaddn TIC LIWIT Das Ue E e do Lr 44 i gu 3 ruua n 3 035 7 dob 32018 8 et Pags 4 bas NOILONnE CLL LHEIT 1 A dans 1d 3 WO Figure 2 yamo MDD 31108 31103 E E 297133 1
19. OR SINGLE BLACK DN TIOYEL 1 DIN CONNECTOR SINGLE YELLOW DNTIOBLU 1 DIN CONNECTOR SINGLE BLUE o Z o o DNTIOGRY 1 CONNECTOR SINGLE GREY _ DN TIOWHT 1 DIN CONNECTOR SINGLE WHITE O Z O Z O DNTIORL 1 DIN RAIL 4INCH 02 03410938 2 SCREW 8 32 X3 8 PHP SS 034 0951 2 NUT NYLOCK 8 32 SS 02 47 Aerial Option Lamp Tree Parts List See Figure 8 HARNESS LAMP AERIAL 2 4 0341017 6 BOLT 20X1 HEX SS BOLT 4 20 X 3 4 HEX 55 034 11029 14 WASHER FLAT SS 6 0341103 4 NUT NYLOCK 20 SS 8 207508020 1 BRACKET NEST AERIAL Figure G KL475 490 Option Lamp Tree Parts List See Figure 8 PART NO 075 08000HS 065 14036 075 90000 065 12852 6 SEALING CONNECTOR 075 08002 49 13 Control Wiring Schematics Control Box Straight Cord PIN BLACK UFFER LIGHTS WHITE 2 ROTATE LEFT RED 3 MIDDLE LIGHTS GREEN 4 GROUND 5 ROTATE RIGHT 6 LOWER LIGHTS 7 CENTER INOICATOR 5 151 STAGE UP 3 zHD STAGE UP 1 STAGE DOWN ORANGE BLUE WHITE BLACK RED BLACK ae ih GREEN BLACK 7 11 TOWER UP LIGHT lis 1 vee BLUE BLACK BLACK WHITE RED WHITE GREEN WHITE BLACK BLUE WHITE WHITE RED GREEM ORANGE BLUE WHITE BLACK RED BLACK GREEN BLAC
20. See Figure 6 0750001 1 TREE COVER METAL HALIDE 03410973 8 SCREW 10 24 X PHP SS DNTIOEB 2 DINNENDBLOCK DNTIORED 1 DIN CONNECTOR SINGLE RED Z DNTIOBIK_ 1 DIN CONNECTOR SINGLE BLACK DNTIOYEL 1 CONNECTOR SINGLE YELLOW DNTIOBLU 1 DIN CONNECTOR SINGLE BLUE DNTIOGRY 1 DIN CONNECTOR SINGLE GREY DNTIOWHT 1 DIN CONNECTOR SINGLE WHITE DNTIORL 1 DN 4 INCH _ 8 SEALCON STRAIGHT 3 8 0544508 8 J SEALCON NUT 3S 1 4 j CABLEI82 SJEOOW 24INCH 034 11017 8 BOLT 20 X 1 HEX SS 04109 16 WASHER FLAT SS 03411033 8 NUT NYLOCK 20 SS Figure 6 46 Metal Halide Option Transformer Compartment Parts List See Figure 7 075 0800 1 LID TRANSFORMER BOX METAL HALIDE 03410938 12 SCREW 832X3 8PPHPSS 5 59 2 3 4 TRANSFORMER 175 W METAL HALIDE 2 11 03410978 36 WASHER INTERNALLOCK l0SS S 03410989 32 1024 88 2 2 L 021523 16 SPACER BRASS A x 3 4 CAPACITOR 175 W METALHALIDE 0561246 4 CLAMP 26 0341073 4 SCREW 10 24 X PHP SS 03410981 4 NUT NYLOCK 10 24SS S DNTIOEB 2 DIN END BLOCK S DMTIORED 1 DIN CONNECTOR SINGLE RED DMTIOBLK 1 DIN CONNECT
21. c tube made of quartz Metal Halide arc tubes operate at high pressure up to 50 p s 1 and at very high temperatures and can unexpectedly rupture due to internal causes such as a ballast failure or misapplication An arc tube rupture can burst and shatter the outer glass bulb resulting in the discharge of glass fragments and extremely hot quartz particles as high as 1832 F 1000 C These lamps can cause serious skin burn and eye inflammation from short wave ultraviolet radiation if the outer envelope of the lamp is broken or punctured Do not use where people will remain for more than a few minutes unless adequate shielding or other safety precautions are used Feature Identification Lamphead Hatchet Back Light Option Upper Actuator Lamp Saddle Mic plate Down Limit Switch Center Switch Stabilizer Arm Lift Arm senal stamped Here Nest Switch Safety Limit Switch Lower Actuator Base Frame 3 Product Safety Precautions 2 2 Never operate the KNIGHT near overhead high voltage power lines The KNIGHT is manufactured from electrically conductive materials 2 G Do not use the KNIGHT for uses other than 15 intended purpose Do not move emergency vehicle with the light extended Visually verify that the light is completely nested before moving vehicle Do not change light position while people are located within its operating envelope There are numerous pinch points that ca
22. d 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 1s 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 15 seldom that any breakage or damage occurs in any of our shipments and in no case will the customer be out any expense 11 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 2 General Description and Specifications The COMMAND LIGHT KNIGHT V2 15 designed to provide high intensity emergency scene lighting with quick precision As with any electromechanical device take precautionary steps to assure safe operation JAN WARNING 2 Never operate the KNIGHT near over
23. ded 95 25 237 Recessed installation 10 Maximum 58 Minimum 24 Minimum Weight 174 pounds Wiring 240 VAC 10 4 SO cord 50 provided Control wiring 22 20 PVC Jacketed 50 provided Relay protection Lights Cole Hersey 3055 40 Other electrical Cole Hersey 3055 40 Current Draw Power Requirements Max 240 VAC Generator Requirement 1500 Watt bulbs 6 amps 4 5 kW minimum 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 0 5 inches per minute 10 seconds to full extension Upper stage 0 5 inches per minute 12 seconds to full extension Rotation 3 25 RPM at lamp tree Full Deployment Lower and upper stages 15 seconds to full actuator extension Auto Park Rotate 180 degees and 40 seconds from full extension retract Operation Angle of vehicle 15 maximum incline Wind load Design maximum 65 mph Maximum tested 55 mph 4500 WATTS 240 VAG WEIGHT 174 LBS 80 Kg INS TAL LATIN ewe 52 rater 1 1 35 3 L RECOMMENDED AREA FOR POWER CORD was S 20 506 MOUNTING HOLE LOCATION 45 1143 47 1194 36 MODEL 495 MINIMUM CLEARANCES FOR CONTROL amp HOLSTER FRONT VIEW SIDE 114 4 12
24. dling the lamps directly leaves minute traces of skin oils that cause localized hot spots that can lead to early lamp failure Lamp surfaces may be cleaned with alcohol Latch the bezel making sure that the weather stripping 1s properly fitted KLA70MH Remove 2 screws that hold the lamp bezel place Use caution The lamp bezel and lens may fall if not properly grasped Caution be certain that the lamp 1s cool to the touch before handling Do not touch the lamp directly Use a clean oil free towel to handle the lamp The lamps operate at high temperatures and high pressure Handling the lamps directly leaves minute traces of skin oils that cause localized hot spots that can lead to early lamp failure Lamp surfaces may be cleaned with alcohol Prior to installing the lamp in the fixture check to be sure the lamp Is of proper type and wattage Screw the lamp securely into the socket back the lamp out one to two turns then screw the lamp back in making sure it 15 secure This properly seats the lamp the socket Refasten the bezel screws making sure that the weather stripping 1s properly fitted 17 1 75 490 Remove 4 screws that hold lamp bezel in place Use caution lamp bezel and lens may fall 1 not properly Caution be certain that the lamp 15 cool to the touch before handling Do not touch the lamp directly Use a clean oil free towel to handle the lamp The lamps operate at high
25. e connections 21 While supporting the actuator remove lamp tree mount arms Use caution the actuator weighs approximately 13 pounds 6kg can cause injury if not supporting adequately Mount arms are universal and can go on either side Note position of lamp tree mount holes in photo at right for proper reassembly position Remove 4 E ring retaining clips securing actuator lower pivot pin in place It is recommended that new E rings be used for reassembly Support actuator and remove lower pivot pin New belt be installed without further disassembly Place belt over rotation platform Starting from one edge begin sliding the belt past the circular dust shields 22 Belt will take some effort to slide past the dust shield Work it over the shield a little at a time Once belt 15 past the shield slide rotation motor towards the center of the motor mount Begin guiding the belt over the drive pulley To assist in getting belt over pulley you can activate the rotation switch on the hand controller to turn the motor Follow previous procedure to adjust the belt tension 23 9 Power Failure 2 The KNIGHT be retracted manually if power to the unit 15 lost If power loss 1s temporary reestablishing power may be easier than manually retracting the light Disconnect all power sources from the KNIGHT Retract the lower stage first S
26. ews that retain rotation motor Make sure both pulleys are parallel and in alignment with each other To adjust any misalignment loosen the 2 set screws securing the small drive pulley to motor shaft Adjust as required and tighten set screws Belt should fit snugly neither too loose nor too tight Avoid any preload which can cause premature failure Using a suitable pry bar apply gentle pressure between rotation motor case and sheet metal motor mount Use caution to not over tighten drive belt Drive belt should have a minimum of 2mm deflection and a maximum of 4mm midway between pulleys when adjusted with the lamp tree positioned as shown in the bottom right photo Rotate lamp tree 180 degrees to verify that belt 15 not too tight If belt is too tight rotation motor noise level will rise noticeably Replace all covers before returning light tower to active service 20 Rotation Drive Belt Replacement Remove midplate covers as outlined previously Raise lamp tree enough to provide easy access to twist lock connectors located above the actuator Disconnect all connectors found The number of connectors will vary depending on what options you model of light tower has Loosen and remove 4 hex head bolts securing lamp tree Slide lamp tree away from rotation platform Lamp tree 15 a tight sliding fit Do not use excessive force If lamp tree does not slide with relative ease verify that you have disconnected all cabl
27. fixed to the relay box Command Light strives to refine the product line We welcome individual input on features and enhancements that would improve our product versatility Questions or comments regarding any of our products please contact us Phone 1 800 797 7974 FAX 1 970 667 4296 Email info commandlight com Web www commandlight com Specifications are subject to change without notice SERIAL HUMBER EARLY MODELS IDEHTIFICATIOH TAG LATE MODELS LOOOTM 9 COMMAND ALL 1 Breakage or Damage During Shipment The transportation company 15 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 write us and we will send you the original bill of lading Get a claim form from the express or truck company Fill the claim form out Attach the claim form to the original bill of lading together with a copy of our invoice Attach a memo on which you show the value of the damaged goods Mail or hand these papers to your local transportation agent They will process your claim with reasonable promptness Please note we cannot and will not enter claims for damages If we file
28. head power lines Power for the 120 240 VAC circuitry 1s provided by the emergency vehicle generator All mechanical actuation power 1s designed to be powered by the internal 12 VDC power supply The umbilical corded control unit is powered via 12 VDC eliminating hazardous voltage levels within the hand held control box EURO specification models incorporate an additional step down transformer for single line 220V AC operation 2 The KNIGHT 1s manufactured to provide years of service with a minimum of maintenance 2 There are several lighting options available for the KNIGHT Model Description Power Requirements KL435 6 x 350 watts 2KW 120 or 240 VAC KL450 6 x 500 watts 4KW 120 or 240 VAC KL470MH 4x 175 watts 2KW 120 or 240 VAC KL475 6 x 750 watts 4 5KW 240 VAC KL490 6 x 900 watts 5 6K W 240 VAC KL495A 3 x 1500 watts 4 5KW 240 VAC Replacement lamps are available from lighting dealers or direct from COMMAND LIGHT Model 435 bulbs are 350 watt 350 3 4 Model 450 bulbs are 500 watt 0500 3 Model 470MH bulbs 175 watt Sylvania M175 U MED ED17 G4479 0 or equivalent Model 475 bulbs are 750 watt Q750T3 CL Model 490 bulbs are 900 watt Q900T3 CL Model 495 bulbs are 1500 watt Q1500T3 CL Metal Halide Precautions WARNING RISK OF ULTRAVIOLET RADIATION EXPOSURE The Knight Light Model KL470MH 15 equipped with METAL HALIDE lamps Metal Halide lamps are constructed of an outer glass bulb with an internal ar
29. his warranty 1s In lieu of and 1s intended to exclude all other warranties express or implied oral or written including any warranties of MERCHANTIBILITY or FITNESS for a particular purpose 97
30. itch plunger surface of accumulated debris switch Lubricate plunger with dry graphite If problem persists replace switch Nest engagement bolt not Lower bolt and or raise switch adjustment contacting switch fully Realign bolt to switch 12VDC power not Trace connections to red green wire and verify present on red green continuity to 12VDC using wiring schematic For a control wire located in replacement wiring schematic please call Command holster box Light 1 800 797 7974 Upper actuator and Down limit switch stuck Clean and dry lubricate switch rotation start Midplate plunger stuck Clean plunger and apply an anti seize compound simultaneously Down limit switch Replace switch defective Autopark stops after Nest switch stuck Clean and dry lubricate switch lamp tree has centered Rubber cover holding Replace rubber cover and lower actuator has nest switch down retracted Upper stage Defective nest switch Replace switch does not retract off center adjustment too severe angle rotate adjustment Center switch defective Center switch defective defective Replace switch 27 Sensor Switch Troubleshooting Rotation Limit Switch item 106 on parts list Nest Switch Located inside relay box Down Limit Switch item 49 on parts list Centering switch item 25 on parts list Mercury switch Provides ground for safety limit relays Prevents operation of lam
31. l the wire feed holes Control Box Holster Mounting Using the holster box as a template mark hole locations Drill g4 mounting holes Drill any holes required to route the control wire from the control box 2 holster to KNIGHT unit Mount holster box with provided hardware 6 Electrical Wiring 2 Run the control wire from the control box to the KNIGHT 2 Run the power wire from the breaker box or generator to the KNIGHT A 40 Amp breaker 15 2 recommended for all models of KNIGHT 2 Make the control connections in the KNIGHT entrance box Light is pre wired to connect to 120 VAC for those lights that support 120 VAC use and can be connected for 240 VAC by removal of factory jumper Model KL495A is wired for 240 VAC only Drill a 14 diameter hole to provide access for routing of power and control wires through vehicle A PVC grommet is provided to provide for a weatherproof installation Use a silicone based sealant under the grommet to assure a weatherproof installation 5 5 Z SS Jor Re 22 1 gt Zx CO 3 i 7 Sy N 0625 AXIMUI SECURE GROMMET U ae eee WIR ACCESS HU 120 VAC Wiring Diagram 240 VAC Wiring Diagram If 240 VAC operation 15 desired remove the jumper wire between the red and black leads GREEN BOND Si 8 0 WHITE eee 1 WHITE NEUTRAL E
32. lowly 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 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 2 punch which could d peen the end ofthe shaft thus damaging the bore within the aluminum pivot blocks Note the upper stage of the light weighs in excess of 100 pounds use caution Apply Remove retaining ring upWw ard pres Sure from lower pivot pin 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 24 Retract the upper staee Support the lamp tree with temporary blocking to relieve the tension the upper actuator pivot pins Unfasten the twist lock connector for the upper actuator
33. n cause serious bodily injury Several components in the KNIGHT contain automatic reset thermal protection Disconnect power at generator distribution panel before servicing the unit Do not use a high pressure washer or subject the light to high volumes of water when cleaning 2 Never use the KNIGHT a lifting device or mobile arm 2 Do not use a KNIGHT that has been damaged or is not fully functional including non working indicator lamps AUTIO DO NOT OPERATE NEAR VOLTAGE OVERHEAD WIRES 2 Never hold any part of the KNIGHT with a hand or foot while it is in motion 9 2 The KNIGHT has numerous pinch points Keep loose clothing hands and feet clear of moving parts CAUTION PINCH POINT 4 Operation Raising light from the nested position 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 2 The KNIGHT has an override system that precludes rotation of the upper stage until the lower stage has elevated 210 from the nested position When the lower stage 15 below 10 a mercury switch controls the following a Upper stage Is prevented from rotating a lights are turned off including strobe light 1f equipped regardless of light switch positions Prevents the upper stage from moving down 11 upper
34. ord 50 provided Control wiring 22 20 PVC Jacketed 50 provided Relay protection Lights Cole Hersey 3055 40 Other electrical Cole Hersey 3055 40 Current Draw Power Requirements Max 240 VAC Generator Requirement 750 Watt bulbs 19 amps 4 5 kW minimum 900 Watt bulbs 24 amps 6 5 kW minimum 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 0 5 inches per minute 10 seconds to full extension Upper stage 0 5 inches per minute 12 seconds to full extension Rotation 3 25 RPM at lamp tree Full Deployment Lower and upper stages 15 seconds to full actuator extension Auto Park Rotate 180 degees and 40 seconds from full extension retract Operation Angle of vehicle 15 maximum incline Wind load Design maximum 65 mph Maximum tested 55 mph pure COMMAND LIGHT KNIGHT NIODEL 475 490 HiH 4 T 1 ist RECOMMENDED AREA FOR POWER CORD s Hill MINIMUM CLEARANCES FOR CONTROL amp HOLSTER INSTALLATION 54 t1427 32 803 5 2 5 E OR HY 7 IE Hr E 34 KL495A Dimensions Height Depth Length Width Retracted 11 375 54 75 23 Exten
35. ps and rotation when lower stage is below 12 inches Normally closed Provides ground for autopark sequence red indicator lamp on controller and vehicle warning device Normally closed Provides ground for autopark sequence Normally open Indicates to autopark upper stage is centered for nest Provides ground for center indicator lamp on controller 28 Lamps will not illuminate upper stage will not rotate Upper stage will not retract during autopark Warning device on vehicle does not deactivate Light will rotate to center lower stage retracts upper stage remains extended Upper stage will not retract during autopark Upper stage not centered Adjust angle of switch replace 1f necessary Inspect protective switch cover for damage Adjust nest switch plunger item 93 on parts list Check down limit plunger item 47 on parts list for freedom of movement Adjust switch as necessary Adjust switch mount and or cam Adjust drive belt tension 11 Technical Specifications KL435 KL450 Dimensions Height Depth Length Width Retracted Ll 47 2 Extended 74 32 23 Recessed installation 10 Maximum 54 Minimum 24 Minimum Weight 136 pounds Wiring 110 VAC 10 4 SO cord 50 provided Control wiring 22 20 PVC Jacketed 50 provided Relay protection Lights Cole Hersey 3055 40 Other electrical Cole Hersey 3055 40 Current Draw Power Requirements Max 110 VAC Max
36. tallation information assistance The screws for the cover are located in a parts bag inside the installation kit box Installation Kit Included with the COMMAND LIGHT 15 an installation kit Verify that the contents of the kit includes the following items 50 feet of I0GA 4 Conductor power cable 1 Pre wired HOLSTER BOX w cover and 50 feet of 20 conductor cable 1 Control Box 1 Small hardware parts bag with 4 mounting spacers 4 16 18 X 2 bolts 4 16 18 nylon lock nuts 4 flat washers 4 large diameter flat washers 2 4 20 X 5 8 pan head Phillips machine screws 12 flat washers 6 14 20 nylon lock nuts 4 4 20 x 1 pan head Phillips machine screw 1 PVC wire grommet 2 4 20 1 socket head cap screw 1 90 degree 12 sealing connector with nut 1 90 degree 34 sealing connector with nut Tools Required Lifting device crane forklift block and tackle etc Sling for lifting Drill lei 6 drill bits Hole saws for metal with 7 8 1 1 8 1 1 4 diameter capacity Phillips head screwdrivers 1 and 2 U combination wrenches and or ratchet and ie and sockets 9 adjustable wrench Wire stripper or razor blade knife Solder less wire connector crimp tool Silicone based gasket sealer recommended 2 The KNIGHT weighs between 136 174 pounds depending upon the model Use mechanical assistance to lift the light into installation position
37. tate off center then press the auto park button and let light tower proceed through sequence until the lamp tree 15 a couple inches above the nested position hit emergency stop Visually determine which side the lamp tree will be hitting the lift arm on Raise lower section above safety limit and to comfortable working height Loosen screw on center switch cam slightly Tap center switch cam away from the side that lamp tree 15 hitting on Fully tighten the screw holding the center switch cam Raise lamp tree to a 45 degree angle rotate off center Press the auto park button and let light tower proceed through sequence until the lamp tree 15 a couple inches above the nested position hit emergency stop If it looks like center is now adjusted properly raise lamp tree to a 45 degree angle and lower stage all the way up press auto park and let it go through the entire sequence If it 15 still hitting off center repeat previous steps If problems adjusting center still persist you may need to adjust the center switch bracket or call Command Light at 1 800 797 7974 to order a new switch part number 069 14222 19 Rotation Drive Belt Adjustment Raise lamp tree to permit easy access Remove the 6 screws that retain the 2 piece midplate cover in place Remove the 4 screws that retains the midplate surround cover Rotate the cover up and away from the main lift arm around the pivot point Loosen but do not remove scr
38. temperatures and high pressure Handling the lamps directly leaves minute traces of skin oils that cause localized hot spots that can lead to early lamp failure Lamp surfaces may be cleaned with alcohol Prior to installing the lamp in the fixture check to be sure the lamp 15 of proper type and wattage Seat the lamp securely into the sockets Refasten the bezel screws making sure that the weather stripping 1s properly fitted KLA95A Remove the 4 screws that hold the lamp bezel in place Use caution The lamp bezel and lens may need to be separated from the housing using a knife edged scraper or similar tool Caution be certain that the lamp 1s cool to the touch before handling Do not touch the lamp directly Use a clean oil free towel to handle the lamp The lamps operate at high temperatures Handling the lamps directly leaves minute traces of skin oils that cause localized hot spots that can lead to early lamp failure Lamp surfaces may be cleaned with alcohol Remove lamp by grasping the left side and pushing the bulb towards the right hand socket Once bulb end 15 clear of the left side socket rotate towards you to remove When inserting bulb insert bulb into the right side socket first Refasten the bezel screws making sure that the weather stripping 1s properly fitted The KNIGHT Is constructed with corrosion resistant aluminum and stainless steel fasteners To further enhance corrosion resistance all exposed surfaces receive a po
39. wder coated paint finish To assure 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 2 Periodic cleaning of all pivot points on the KNIGHT with a moisture displacing cleaner and soft bristle brush without disassembly to remove accumulated dirt and debris will minimize wear 18 Center Switch Cam Adjustment 2 Symptom KNIGHT lamp tree 15 not returning to center during AutoPark Solution Adjust center switch activating cam Listed below are the steps to follow to adjust cam correctly Note By making a mark next to the cam on the bottom of the spindle this makes judging distance much easier Having the lamp tree at either extreme of fully up or down will affect the degree of centering The optimum 15 achieved by adjusting it at a 45 degree angle If problems persist please call Command Light at 1 800 797 7974 Raise lamp tree to a 45 degree angle raise lower section high enough to comfortably work on and make sure you are above the set safety limit 1 6 Lights will turn on Visually check to see that the centering cam on the rotation spindle is contacting the center switch Ro
40. ximity to the entrance 5 16 FLAT WASHER box on the light ta The control box should be mounted in 6 area shielded from the weather Allow minimum of 10 clearance above the control box mounting location to permit easy removal of the hand controller PLASTIC SPACER VEHICLE BODY LARGE DIAMETER I J FLAT WASHER 5 16 LOCK NUT 11 Mounting Place the provided spacers in the location of the light mounting holes The spacers may be 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 unit The center of gravity balance point 1s slightly behind the lower bank of lights Approximate center of gravity location 2 Slowly lift the KNIGHT check for balanced lifting Lower and make any necessary adjustments to the lift points 2 Lift and place the KNIGHT 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 Drill 4 holes in the mounting surface using the end frame holes as a template Fasten the light using the provided hardware To assure a weather tight installation apply a thin bead of silicone based gasket sealer to the base of the spacer and under side of bolt head Remove any lifting straps and devices from the light Locate and dril
41. y COMMAND LIGHT for repair or replacement under this warranty without specific written authority from COMMAND LIGHT 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 15 tested before leaving our plant and 1s 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 discernable when the equipment 15 returned to us for inspection 2 On all component parts not manufactured by COMMAND LIGHT their warranty 15 to the extent that the manufacturer of such component warrants them to COMMAND LIGHT 1f 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 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 T
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