Command Light CLSeries User manual

CL SERIES
Eective August 2021
is guide supersedes all previous versions
MODEL COVERED:
CL602A
3842 Redman Drive
Fort Collins, CO 80524
1-800-797-7974
www.CommandLight.com

COMMAND LIGHT
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THANK YOU
Please allow us to express a simple thank you for investing in a COMMAND LIGHT product.
As a company, we are dedicated to producing the very best and most versatile ood lighting
package available. We take great pride in the quality of our work and hope that you will nd
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.
3842 Redman Drive
Fort Collins, CO 80524
PHONE: [phone]
FAX: [phone]
WEB: www.CommandLight.com

USER GUIDE
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COMMAND LIGHT
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Please take the time to read this manual before installing or operating
the COMMAND LIGHT.Save this guide for future reference.
Contents
Warranty..................................................................................................................................................... 4
Breakage or Damage During Shipment ................................................................................................... 5
Product Safety Precautions ....................................................................................................................... 6
General Description and Specications ................................................................................................... 7
Operation.................................................................................................................................................... 8
Raising the light from the nested position.......................................................................................... 9
Returning the light to the nested position .................................................................................................... 9
Installation................................................................................................................................................ 10
Installation Kit.................................................................................................................................. 10
Tools Required.................................................................................................................................. 10
Installation Notes.............................................................................................................................. 10
Location Requirements..................................................................................................................... 11
Mounting .......................................................................................................................................... 12
Electrical Wiring ...................................................................................................................................... 13
120 VAC Wiring Diagram (120 VAC, 240 VAC, 220 VAC)............................................................ 13
Holster Wiring .................................................................................................................................. 13
Warning Device Installation ............................................................................................................. 14
Maintenance ............................................................................................................................................. 15
Cleaning............................................................................................................................................ 15
Rotation Belt Adjustment ................................................................................................................. 16
Center Switch Adjustment................................................................................................................ 17
Light Tower is Not Finding Center................................................................................................... 17
Power Failure ........................................................................................................................................... 18
Rotate to center................................................................................................................................. 18
Retract the upper stage. .................................................................................................................... 18
Retract the lower stage ..................................................................................................................... 18
Troubleshooting........................................................................................................................................ 19
Holster Circuit Board Error Codes........................................................................................................ 20
Technical Specications – Standard AC Models (602A) ...................................................................... 21
Specications.................................................................................................................................... 22
Parts Lists - Exploded Views................................................................................................................... 23
Exploded View (Lower Stage A).................................................................................................24-25
Exploded View (Lower Stage B).................................................................................................26-27
Exploded View (Upper Stage A) .................................................................................................28-29
Exploded View (Upper Stage B) .................................................................................................30-31
Exploded View (Lamp Tree) .......................................................................................................32-33
Relay Box ....................................................................................................................................34-36
Entrance Box .................................................................................................................................... 37
Wiring Schematics ................................................................................................................................... 38
Entrance Box (120VAC, 220VAC, 240VAC)..............................................................................38-40
Holster Box..................................................................................................................................41-42
OPS Wireless Controller (VMUX/Wireless Systems) ..................................................................... 43
Lamp Tree (Strobe, Backlight) ....................................................................................................44-45
Midplate............................................................................................................................................ 46
Relay Box ......................................................................................................................................... 47

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Command Light PHONE: [phone]
3842 Redman Drive FAX: [phone]
Fort Collins, CO 80524 WEB: www.CommandLight.com
COMMAND LIGHT 5 YEAR LIMITED WARRANTY
COMMAND LIGHT products* come with an industry leading 5-year warranty against any defects in
materials and workmanship when used and operated for a period of ve years. The responsibility of
COMMAND LIGHT under this limited warranty is limited to the repair and replacement of parts found
to be defective by COMMAND LIGHT.
Any parts damaged in shipping or by improper installation, overloading, abuse, or accident of any type
or cause are not covered by this warranty. If equipment has been damaged in transit, a claim should be
made against the carrier within three days, as we assume no responsibility for such damage.
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 the
COMMAND LIGHT warranty.
1. Contact us immediately for initial diagnosis at [email protected] or 800-797-7974; or if
parts are needed contact [email protected].
2. You will need to have immediate access to the light tower and the serial number. 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 an authorized technician dispatched (if needed) with a
written work authorization number and a base number of hours allotted to do repair. Hourly rates for
service are to be determined at the time of authorization by COMMAND LIGHT, travel time is paid at
a maximum of 50% of the authorized service rate.
4. We remain available for service support via phone, email, or video conference while the technician
completes the repair, also to extend the original time allotted if additional issues arise. Immediate
support cannot be guaranteed unless a time is scheduled prior to service.
5. Let us know when the repair is completed and reference the work authorization number. Email an
invoice to [email protected] or [email protected]. If you are unable to create an
invoice email us for instructions for payment. Make sure any parts we have requested to be returned
have been shipped back to the provided shipping address. If a return label is issued it must be used.

COMMAND LIGHT
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6. Finally, we will pay by mailing a check or crediting the account of the person, department, or company
doing the repair. Payments will not be made until all requested parts have been returned.
Please contact us as soon as problems arise in order to execute our warranty. We must have knowledge of
the issue and provide a work authorization in order to pay or reimburse labor or travel time.
Any unauthorized service voids this warranty. No work is authorized until written consent is provided by
COMMAND LIGHT.
Contact Us Early — before any work is done — We’d love to help!
*Excludes light producing components (bulbs, lasers, LEDs) These components may 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 nd 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 ling a claim. Each company will have a unique
procedure to follow.
Please note, we cannot and will not enter claims for damages. If we led a claim here, it would be sent to
your local freight agent for verication and investigation. This time can be saved by you ling the claim
directly. Every consignee is on the ground oor, 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 le 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 sometime 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.

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Product Safety Precautions
[Never operate the COMMAND LIGHT near
overhead high voltage power lines. The
COMMAND LIGHT is manufactured from
electrically conductive
materials.
[Do not use the COMMAND LIGHT for uses
other than its 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 can cause serious bodily injury.
[Do not use a high-pressure washer or subject the light to high volumes of water when cleaning.
[Never use the COMMAND LIGHT as a lifting device or mobile arm.
[Do not use a COMMAND LIGHT that has been damaged or is not fully functional,
including non-working indicator lamps.
[Never hold any part of the COMMAND LIGHT with a hand or foot while it is in
motion.
[The COMMAND LIGHT has numerous pinch points. Keep loose clothing,
hands and feet clear of moving parts.

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General Description and Specications
The COMMAND LIGHT is designed to provide high intensity emergency scene lighting with quick
precision. As with any electromechanical device, take precautionary steps to assure safe operation.
Never operate the COMMAND LIGHT near overhead power lines.
ere are several standard lighting options available for the COMMAND LIGHT.
Model # Description Minimum Power Requirements
CL602A 6 x LED 2KW, 110 OR 240 VAC
The emergency vehicle generator provides power for the 110/240 VAC circuitry. All mechanical
actuation is powered by an internal power supply. The umbilical corded control unit is powered via 12
VDC eliminating hazardous voltage levels within the hand held control box.
The COMMAND LIGHT is manufactured to provide years of service with a minimum of maintenance.

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Operation
Raising the 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.
The COMMAND LIGHT 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 COMMAND LIGHT before turning on lights.

COMMAND LIGHT
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Returning the light to the nested position
The COMMAND LIGHT is equipped with an Autopark function as a standard feature. The “P” button
on the control box initiates the Autopark sequence. Once initiated, the “Emergency Stop” 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 oscillation 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.

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Installation
The COMMAND LIGHT must be installed by a designated installation facility by qualied 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 COMMAND LIGHT is an installation kit. Verify that the kit contains the
following items:
(1) 50 feet of 10GA-4 Conductor power cable (1) 50 feet of 22GA-20 conductor cable
(1) Pre-wired HOLSTER BOX w/cover (1) Handheld Controller
(1) Lifting sling
(1) Small hardware parts bag with:
(4) mounting spacers (4) 3⁄8-16 X 2 ½" bolts
(4) 3⁄8-16 nylon lock nuts (8) 3⁄8" at washers
(4) large diameter at washers (2) ¼-20 X 5⁄8" Phillips pan head machine screws
(4) ¼" at washers (2) ¼-20 nylon lock nuts
(1) ½" 90° sealing connector w/nut (1) 1" 90° sealing connector w/nut
(4) screw pin clevis
Tools Required
Lifting device (crane, forklift, block and tackle, etc.)
Sling for lifting (included with light)
Drill
13/32", 17/64" drill bits
Hole punch for metal with 7/8" and 15/16" diameter capacity
Phillips head screwdriver, #2
COMMAND LIGHT at blade screwdriver (included with light)
9/16" and ½" combination wrenches and/or ratchet and 9/16" and ½" 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 COMMAND LIGHT weighs approximately 300 pounds. Use mechanical assistance to lift the
light into installation position such as a forklift or crane.
• Use the provided sling to grasp the light.
• 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 COMMAND LIGHT is not designed to be operated in a raised position while the vehicle is in
motion. The COMMAND LIGHT includes warning circuit wiring to enable a warning device.

COMMAND LIGHT
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Location Requirements
The standard COMMAND LIGHT CL602A model can be mounted on any location that is 73" x 36".
The surface should be at or have only a slight crown. For a recessed installation allow for a minimum
of 86" x 48". Consult with factory before construction of recessed installation. Verify all dimensions
before installation to assure proper operation of light will not infringe on other installed components.
For all other installations refer to the dimensional drawing on page 22 of this guide that represents
your particular model of light. The drawings reect the dimensions of the “working envelope” of
a typical light. Make certain sufcient clearances are incorporated in your installation to allow for
variations (vehicle body ex, 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. Eight holes are provided to allow the installer to avoid
obstructions when mounting the light. 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 entrance box on the light.
Installing the cords with a sweeping 90º or 180º 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.

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Mounting
Place the provided spacers in the location of the light mounting holes. The spacers may be modied 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 COMMAND LIGHT. The center of gravity (balance
point) is slightly behind the lower bank of lights.
Slowly lift the COMMAND LIGHT and check
for balanced lifting. Lower and make any
necessary adjustments to the lift points.
Slowly lift the COMMAND LIGHT and
check for balanced lifting. Lower and make
any necessary adjustments to the lift points.
Lift and place the COMMAND LIGHT 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 13/32" holes in the mounting
surface using the end casting 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 underside of bolt head.
Remove any lifting straps and devices from the COMMAND LIGHT.
Locate and drill the wire feed holes.
Control Box Holster Mounting
Using the holster as a template, mark hole locations.
Drill 17/64" mounting holes.
Drill any holes required to route the control wire from the control box to the COMMAND LIGHT unit.
Mount holster box with provided hardware.

COMMAND LIGHT
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Electrical Wiring
Please Note: Detailed internal wiring schematic for the light is found in the supplement pages found at
the end of this document.
Run the control wire from the control box holster to the COMMAND LIGHT.
Run the power wire from the breaker box or generator to the COMMAND LIGHT. A 40 Amp breaker
is recommended on AC models.
Make the control connections in the COMMAND LIGHT entrance box. To simplify installation remove
the connector hold down screws and pull the connector out of the box slightly.
The Model CL602A series COMMAND LIGHT comes pre-wired to connect to 120 VAC.
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.
120 VAC Wiring Diagram 240 VAC Wiring Diagram
If 240 VAC operation is desired, remove the
jumper wire between the red and black leads.
220 VAC European Wiring Diagram
If the light tower is ordered with 220 VAC (Single
Hot Leg) wiring, only use a single hot conductor
from the power source, the other is not needed.

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Warning Device Installation
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
on pages 41 and 42. 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
Make sure the tab on the coil cord connector lines up with the slot on the controller connector. Rotate
the coil cord connector clockwise until nger tight. DO NOT use tools to tighten this connector.

COMMAND LIGHT
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Maintenance
Cleaning
The COMMAND LIGHT is constructed with corrosion resistant aluminum and stainless steel fasteners.
To further enhance corrosion resistance all exposed surfaces receive a powder coated paint nish.
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. 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 COMMAND LIGHT 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.
Rotation Motor Replacement
1. Raise the lamp tree fully. Loosen the center switch
screw. Take off the midplate covers. Carefully remove
the smaller cover, maneuvering around the Turck
sensor and wire.
2. Loosen the motor screws enough to slide back and
forth. Rotate the upper lamp tree and locate the master
link in the rotation chain. Position the master link to
an available and comfortable place to remove. Once
disconnected, remove chain.
Note: The upper lamp tree will now rotate freely.
3. Using a 3/32 allen wrench, Remove the two set
screws in the small sprocket. Gently pull off the
small sprocket.
4. Remove the bottom motor box cover. Carefully pull
out the pole strip and all connected wires.

Center Switch Screw

USER GUIDE
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5. Follow the two motor wires down to the pole strip
and disconnect. Brown wire (negative) red/white wire
(Positive).
Note: The same wires that come off the old motor will
be the same wires you use for the new rotation motor.
Swap the wires from the old motor to the new motor.
Now the new motor can be installed.
6. Attach the wires to the new motor (the brown is
negative and the red/white is positive) and connect
them to the pole strip. Place the motor back into the
housing and screw in all four screws. Rotate the motor
so the key stock slot is facing you.
7. Place the small sprocket back on the motor and put
in the keystock. Use blue Loctite on the set screws
tightening them as much as possible.
8. If not already, loosen up the four motor screws to let
the motor slip for adjustment. Wrap the chain back
around the sprockets bringing the ends together.
Note: Be sure the half-link is on the right hand side
with the small cotter pin facing upwards.
9. Using a small pry bar or a screw driver, put pressure
on the small sprocket pushing it away and tightening
the chain. Tighten down the four motor screws.
10. Now the bottom box cover can be put back on after
placing all the wires back in place. The mid plate
covers can now be put back on also.
Note: After motor replacement is completed, the
center switch and the safety switch will need to be
adjusted.

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Center Switch Adjustment
Exercise caution when performing the following procedure. There are numerous pinch points that can
cause severe injury. Adjustment should be performed by qualied personnel.
1. Raise lamp tree fully. Raise lower stage enough to comfortably work on. Verify lower stage is above
the safety limit, lamps can be illuminated.
2. Visually inspect the screw on the rotation platform to be sure it is activating the Turck sensor. The
green light on the sensor indicates it has power. The orange light indicates the sensor is activated.
3. Rotate off center. Activate Autopark and let light tower proceed through sequence until the lamp tree
is a couple inches above the nested position, hit Emergency Stop.
4. Visually determine which side the lamp tree will be hitting the nest pad.
5. Raise lower section above safety limit and to comfortable working height.
6. Loosen screws on center switch bracket slightly.
7. Tap center switch bracket slightly toward the side that the lamp tree is hitting on.
8. Fully tighten the screws holding the center switch bracket.
9. Raise lamp tree all the way up, rotate off center.
10. Press the Autopark button and let light tower proceed through sequence until the lamp tree is a couple
inches above the nested position, hit Emergency Stop.
11. If it looks like center is now adjusted properly, raise light tower all the way up one last time and press
Autopark and let it go through the entire sequence.
12. If it is still hitting off center, repeat steps 3-11. If problems adjusting center still persist you may need
to adjust the height on the set screw, or call Command Light at 1-800-797-7974 to order a new switch
part number 065-12884.
1. Visually check to see if the orange indicator light is activating with metal in proximity and that the
green light is on constantly.
2. Check continuity of white/black wire in relay box to the connection point in the box below the mid-
plate. White/black should connect to the black wire from the Turck sensor.
Light Tower is Not Finding Center

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Power Failure
The COMMAND LIGHT can be retracted manually if power to the unit is lost. If power loss is
temporary, reestablishing power may be easier than manually retracting the light.
Note: Disconnect power source from the COMMAND LIGHT before manual operation.
WATCH THE VIDEO AT WWW.COMMANDLIGHT.COM/TECHNICAL-VIDEOS/
Rotate to center
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. Be certain
that you rotate the platform in the proper direction. The upper stage can rotate a full 360˚. Generally
you need to rotate the platform in the direction that requires the least amount of travel in order to center
the platform.
Retract the Lower Stage
Locate the silver plug located on lower actuator below the lower actuator’s motor. Use the provided hex
tool to remove silver plug. Be sure to not lose this plug. Use the same hex tool inserted into the opening
to drive the internal gears of the actuator. Be sure to replace the silver plug after this actuator is fully
retracted. Be careful not to hit the lower lamps on main electrical box if your tower has the Backlight
option and the lamps are not ush with the xed lamps.
Retract The Upper Stage
To access the upper actuator mechanism it is necessary to remove the main cover. Remove
the 16 screws using a #2 Phillips head screwdriver. There are 12 screws on top and 2 on
either end of the main cover. Use the same hex bit and method as above in “Retract The
Lower Stage First” to retract the upper actuator.

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Troubleshooting
Problem Possible Cause Solution
Unit will not extend 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 lament broken. Replace lamp.
Rotation coasts after switch
is released
Drive chain out of
adjustment
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
>5°.
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
Improper or faulty ground Check nest switch ground
and operation. Test red/green
wire for 12VDC.
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
Check down limit sensor. Contact factory for
replacement part.
Wires on back light catching Check for 90 degree sealing con-
nector 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 17
Popping noise coming
from back light
Drive belt loose, switch hoods
stuck, faulty rotation relay.
Adjust belt for minimal
play. Replace switch hoods.