Command Light CLSeries User manual

CL Series

COMMAND LIGHT
2
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 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: [phone]
FAX: [phone]
WEB: www.CommandLight.com

USER GUIDE
3

COMMAND LIGHT
4
Please take the time to read this manual before installing or operating the COMMAND LIGHT.
Save this guide for future reference.
Contents
Warranty ................................................................................................................................................................................6
Breakage or Damage During Shipment...............................................................................................................................7
Product Safety Precautions...................................................................................................................................................8
General Description and Specifications ...............................................................................................................................9
Operation ..............................................................................................................................................................................10
Controller Functions ................................................................................................................................................ 10
Raising the light from the nested position .............................................................................................................. 10
Returning the light to the nested position .............................................................................................................. 11
Installation............................................................................................................................................................................11
Installation Kit ......................................................................................................................................................... 11
Tools Required ........................................................................................................................................................ 12
Installation Notes .................................................................................................................................................... 12
Location Requirements ........................................................................................................................................... 13
Mounting ................................................................................................................................................................. 14
Electrical Wiring..................................................................................................................................................................15
120 VAC Wiring Diagram ......................................................................................................................................... 15
240 VAC Wiring Diagram ......................................................................................................................................... 15
220 VAC European ................................................................................................................................................... 16
Holster Wiring ......................................................................................................................................................... 16
Warning Device Installation .................................................................................................................................... 17
Maintenance .........................................................................................................................................................................18
Bulb Replacement ................................................................................................................................................... 18
Cleaning ................................................................................................................................................................... 18
Rotation Motor Replacement ............................................................................................................................ 19-20
Center Switch Adjustment ...................................................................................................................................... 21
Light Tower is Not Finding Center ........................................................................................................................... 21
Power Failure .......................................................................................................................................................... 22

USER GUIDE
5
Troubleshooting ...................................................................................................................................................................23
Holster Circuit Board Error Codes ...................................................................................................................................24
Technical Specifications ...................................................................................................................................................... 25
Dimensional Specifications..................................................................................................................................................26
Parts Lists - Exploded Views ..............................................................................................................................................27
Lower Stage Parts List A .......................................................................................................................................... 27
Exploded View (Lower Stage A) ............................................................................................................................... 28
Lower Stage Parts List B .......................................................................................................................................... 29
Exploded View (Lower Stage B) ............................................................................................................................... 30
Upper Stage Parts List A .......................................................................................................................................... 31
Exploded View (Upper Stage A) ............................................................................................................................... 32
Upper Stage Parts List B .......................................................................................................................................... 33
Exploded View (Upper Stage B) ............................................................................................................................... 34
Upper Stage Parts List C .......................................................................................................................................... 35
Exploded View (Upper Stage C) ............................................................................................................................... 36
Wiring Schematics ...............................................................................................................................................................37
Relay Box ................................................................................................................................................................. 37
Entrance Box (120VAC) ........................................................................................................................................... 38
Entrance Box (220VAC) Single Leg ........................................................................................................................... 39
Entrance Box (240VAC) Dual 120 Legs .................................................................................................................... 40
Holster Box Splitter Box Multiplex - or Wireless .................................................................................................... 41
Dual Controller ........................................................................................................................................................ 42
Lamp Tree Backlight ................................................................................................................................................ 44
Lamp Tree (Strobe) .................................................................................................................................................. 45
Midplate .................................................................................................................................................................. 46

COMMAND LIGHT
6
Command Light
PHONE:
1-800-797-7974
3842 Redman Drive
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 discernable 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 is paid at a maximum of 50% and only if pre-approved.

USER GUIDE
7
Warranty/Service
COMMAND LIGHT products* come with a industry leading 5 year warranty against any defects in materials 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]m
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 problemspromptly 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.

COMMAND LIGHT
8
Product Safety Precautions
XNever operate the COMMAND
LIGHT near overhead high
voltage power lines. The
COMMAND LIGHT is
manufactured from electrically
conductive materials.
XDo not use the COMMAND
LIGHT for uses other than its
intended purpose.
XDo not move emergency vehicle with the light extended. Visually verify that
the light is completely nested before moving vehicle.
XDo not change light position while people are located within its operating
envelope. There are numerous pinch points that can cause serious bodily injury.
XDo not use a high-pressure washer or subject the light to high volumes of water
when cleaning.
XNever use the COMMAND LIGHT as a lifting device or mobile arm.
XDo not use a COMMAND LIGHT that has been damaged or is not fully
functional, including non-working indicator lamps.
XNever hold any part of the COMMAND LIGHT with a hand or foot while it is
in motion.
XThe COMMAND LIGHT has numerous pinch points. Keep loose clothing,
hands and feet clear of moving parts.

USER GUIDE
9
General Description and Specifications
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.
There are several standard lighting options available for the COMMAND LIGHT
Model #
Description
Minimum Power Requirements
CL605
6 x 500 watts
3KW, 110 or 240 VAC
CL607
6 x 750 watts
5KW,110 or 240VAC
CL611
6 x 1000 watts
6KW, 240 VAC
CL615
6 x 1500 watts
9KW, 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.

COMMAND LIGHT
10
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
activations.
• 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.

USER GUIDE
11
Returning the light to the nested position
The COMMAND LIGHT is equipped with an Autopark function as a standard feature. The
“P” 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 “P” 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. Controller will need to be
re-energized after “Emergency Stop” or nest is activated.
Installation
The COMMAND LIGHT 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 COMMAND LIGHT is an installation kit. Verify that the kit contains the
following items:
(1) 50 feet of 8GA-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" 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
(1) ½" 90° sealing connector w/nut (1) 1" 90° sealing connector w/nut
(4) screw pin clevis

COMMAND LIGHT
12
Tools Required
Lifting device (crane, forklift, block and tackle, etc.)
Sling for lifting (included with light)
Drill
3⁄8", 17⁄64" drill bits
Hole punch for metal with 7⁄8"and 17⁄64" diameter capacity Phillips head screwdriver, #2
COMMAND LIGHT flat blade screwdriver (included with light)
9⁄16" and 1⁄2" combination wrenches and/or ratchet and 9⁄16" 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 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.

USER GUIDE
13
Location Requirements
The standard COMMAND LIGHT Models 605,607,611,615 can be mounted on any
location that is 73” x 36”. The surface should be flat 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 included in the beginning pages of this guide
that represents your particular model of light. The drawings reflect the dimensions of the
“working envelope” of a typical light. 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. 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 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.

COMMAND LIGHT
14
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 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.
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.

USER GUIDE
15
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.
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 605/607 series COMMAND LIGHT comes pre-wired to connect to 120 VAC.
A 40 Amp breaker is recommended.
The Model 611/615 series COMMAND LIGHT comes pre-wired to connect to 240 VAC.
A 50 Amp breaker is recommended.
120 VAC Wiring Diagram
240 VAC Wiring Diagram
If 240 VAC operation is desired, remove the jumper wire between the red and black leads.

COMMAND LIGHT
16
220 VAC European
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.
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

USER GUIDE
17
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. 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.
2.) Loosen
the large nut.
3.) Gently slide the
connector away
from the holster.
4.) Disconnect the
cable by pressing down
on the tab and pulling.
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.

COMMAND LIGHT
18
Maintenance
Bulb Replacement
Tools required:
Clean oil-free cloth, Cleaning alcohol
Replacement bulbs:
Model 605 bulbs 500 watt, Q500T3/CL
Model 607 bulbs 750 watt, Q750T3/4CL
Model 611 bulbs 1000 watt, Q1000T3/CL
Model 615 bulbs 1500 watt, Q1500T3/CL
Bulbs are available from General Electric, Sylvania, Phillips, Grainger or direct from
COMMAND LIGHT.
Position lamp tree so lamps are readily accessible. This is usually with the lower stage in the
retracted position and the upper stage extended to 90˚.
Disconnect the power supply from the COMMAND LIGHT. Allow sufficient time for
lamps to cool. The surrounding metal lamp housing can cause serious burns.
Caution: Be certain that the bulb is cool to the touch before handling. Do not touch the bulb
directly. Use a clean oil-free towel to handle the bulb. Handling the bulbs directly
leaves minute traces of skin oils that cause localized hot spots that can lead to early
bulb failure. Bulb surfaces may be cleaned with alcohol.
Latch the bezel making sure that the weather stripping is properly fitted. Weather
stripping must be properly installed to ensure lamp water tightness.
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 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. The actuators have internal limit switches at each end of the stroke. 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.

USER GUIDE
19
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.
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.
Center Switch Screw

COMMAND LIGHT
20
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.