Command Light KL409A User manual

Eective August 2021
is guide supersedes all previous versions
MODEL COVERED:
KL409A
3842 Redman Drive
Fort Collins, CO 80524
1-800-797-7974
www.CommandLight.com
KNIGHT SLIMKNIGHT SLIM

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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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Read this manual before installing or operating the
COMMAND LIGHT KNIGHTSLIM.
Save this guide for future reference.
Contents
Warranty..................................................................................................................................................... 4
Warranty/Service ................................................................................................................................ 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.......................................................................................... 8
Returning the light to the nested position........................................................................................... 9
Installation................................................................................................................................................ 10
Installation Kit.................................................................................................................................. 10
Tools Required.................................................................................................................................. 10
Installation Notes.............................................................................................................................. 10
Location Requirements..................................................................................................................... 11
Mounting .......................................................................................................................................... 12
Holster Mounting.............................................................................................................................. 13
Electrical Wiring ...................................................................................................................................... 13
120 VAC ........................................................................................................................................... 13
Holster Wiring .................................................................................................................................. 13
Warning Device Installation ............................................................................................................. 14
Relay Box Wiring........................................................................................................................15-16
Maintenance ............................................................................................................................................. 17
Cleaning............................................................................................................................................ 17
Center Switch Adjustment...........................................................................................................17-18
Rotation Belt Adjustment ................................................................................................................. 18
Power Failure ........................................................................................................................................... 19
Rotate to center .......................................................................................................................................... 19
Retract the upper stage. .................................................................................................................... 19
Retract the lower stage ..................................................................................................................... 19
Without tools .................................................................................................................................... 20
Troubleshooting........................................................................................................................................ 21
Error Codes on Holster Circuit Board................................................................................................... 22
Technical Specications – Standard AC Models (409A-H4)................................................................ 23
Specications.................................................................................................................................... 24
Parts Lists - Exploded Views................................................................................................................... 25
Exploded View (Base) .................................................................................................................26-27
Exploded View (Midplate) .......................................................................................................... 28-29
Exploded View (Lamp Tree) ............................................................................................................ 30
Relay Box .................................................................................................................................... 31-33
Wiring Schematics ................................................................................................................................... 34
Relay Box ......................................................................................................................................... 34
Holster Box..................................................................................................................................35-36
OPS Wireless Controller (VMUX/Wireless Systems) ..................................................................... 37
Midplate............................................................................................................................................ 38
Lamp Tree......................................................................................................................................... 39

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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 i[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.

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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 KNIGHTSLIM
near overhead high voltage power lines. The
COMMAND LIGHT KNIGHTSLIM is manufactured
from electrically conductive
materials.
[Do not use the COMMAND LIGHT KNIGHTSLIM 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 KNIGHTSLIM as a lifting device or mobile arm.
[Do not use a COMMAND LIGHT KNIGHTSLIM that has been damaged or is not fully functional,
including non-working indicator lamps.
[Never hold any part of the COMMAND LIGHT KNIGHTSLIM with a hand or foot while it is in
motion.
[The COMMAND LIGHT KNIGHTSLIM has numerous pinch points. Keep loose clothing,
hands and feet clear of moving parts.

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General Description and Specications
The KNIGHTSLIM is designed to provide high intensity emergency scene lighting with quick precision.
As with any electromechanical device, take precautionary steps to ensure safe operation.
Never operate the KNIGHTSLIM near overhead power lines.
ere are several standard lighting options available for the KNIGHTSLIM.
Model # Description Minimum Power Requirements
KL409A-H4 4 x LED 960w, 115V AC
The emergency vehicle provides power for the 12 VDC elevated warning device circuitry. The
umbilical corded control unit is powered via 12 VDC eliminating hazardous voltage levels within
the hand held control box.
The KNIGHTSLIM is manufactured to provide years of service with a minimum of maintenance.
Identication Tag

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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 KNIGHTSLIM 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 KNIGHTSLIM before turning on lights.

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Returning the light to the nested position
The KNIGHTSLIM 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 KNIGHTSLIM 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 KNIGHTSLIM 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) Small hardware parts bag with:
(4) mounting spacers (4) 5∕16 -18 x 2 ½” bolts
(4)
5∕16 -18 nylon lock nuts (8) 5∕16” 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
Tools Required
Lifting device (crane, forklift, block and tackle, etc.)
Sling for lifting
Drill
21/64", 17/64" drill bits
Hole punch for metal with 7/8" and 15/16" diameter capacity
Phillips head screwdriver, #2
COMMAND LIGHT at blade screwdriver (included with light)
7/16” and 1/2” combination wrenches and/or ratchet and 7/16” and 1/2” sockets
8” adjustable wrench
Tongue and Groove Pliers
Wire stripper or razor blade knife
Solder-less wire connector crimp tool
Silicone based gasket sealer, RTV™ recommended
Installation Notes
The KNIGHTSLIM weighs approximately 165 pounds. Use mechanical assistance to lift the
light into installation position such as a forklift or crane.
Use the provided fender washers under the mounting surface to distribute the weight load evenly.
When routing the connecting electrical wires take care to avoid sharp bends, hot components or other
hazards to the wire.
The KNIGHTSLIM is not designed to be operated in a raised position while the vehicle is in motion.
The KNIGHTSLIM includes warning circuit wiring to enable a warning device.

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Location Requirements
The standard KNIGHTSLIM 409 models can be mounted on any location that is 53" x 13", additionally
allow for a minimum of 3" of space around the perimeter of the nested tower. The surface should be
at or have only a slight crown. For a recessed installation, allow for a minimum of 3" of space around
the perimeter of the tower taking into consideration the dimensions of the tower both fully nested and
fully elevated. Consult with factory before construction of recessed installation. Verify all dimensions
before installation to ensure proper operation of light will not infringe on other installed components.
For all other installations refer to the dimensional drawing on page 24 of this guide that represents
your particular model of light. The drawings reect the dimensions of the “working envelope” of a
typical light tower. 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
model is not represented, call or email the factory prior to beginning any construction of a recessed
installation. This model also requires an 18" x 7" x 5" electrical box mounted near the tower.
Four mounting bolt holes are required. Additional holes may be drilled in the frame ends if necessary to
clear obstructions.
Access holes for the power cord cabling should be in close proximity to the relay box access holes on
the light. Installing the cords with a sweeping 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 KNIGHTSLIM. The center of gravity (balance point) is
slightly behind the lower bank of lights.
Slowly lift the KNIGHTSLIM and check for balanced lifting. Lower and make any necessary
adjustments to the lift points.
Lift and place the KNIGHTSLIM into position above the spacers. Before placing the full weight of the
unit on the spacers align spacers with the holes in the end frame castings.
Drill 21/64” holes in the mounting surface using
the end casting holes as a template.
Fasten the light using the provided hardware.
To ensure a weather-tight installation apply
a thin bead of silicone based gasket sealer to
the base of the spacer and underside of bolt
head.
Remove any lifting straps and devices from
the
KNIGHTSLIM.
Locate and drill the wire feed holes.

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Electrical Wiring
Please Note: Detailed internal wiring schematics are located at the back of this user guide.
Run the control wire from the control box holster to the KNIGHTSLIM.
Run the power wire from the breaker box or generator to the KNIGHTSLIM. An 20 Amp breaker is
recommended on AC models.
Make the control connections in the KNIGHTSLIM relay box.
The Model KL409A series KNIGHTSLIM comes pre-wired to connect to 115 VAC.
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.
Holster Mounting
Using the holster mount as a template, mark hole locations.
Drill 17/64” mounting holes.
Drill any holes required to route the control cable from the holster to the KNIGHTSLIM relay box.
Attach the holster to the holster mount with the provided hardware.

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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 35 and 36. 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.

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KL409A (KL Slim) Relay Box Wiring
Tools Required:
• 1/8" Flathead Screwdriver
• #2 Phillips Screwdriver
• Wire Strippers
• 7/16" Nut driver or Wrench
• Wire Crimpers
• Large Cable Crimpers
• Bosch Crimpers
• 15/16", 1 1/16", 1 5/8" Wrenches or Channel Locks
• Small torch or lighter
Route Cables from Light Tower to Relaybox
Crimp Large Bosch connectors on the 10 Awg black, red, blue, & orange wires in the larger cable, these
are the Lamp Power wires. Insert the Bosch connectors into the open slot in the relay modules and then
insert the relays.
Crimp 10-12 Awg / ¼" ring connectors on the 10 Awg white, gray, yellow, & yellow/black wires in
the larger cable, these are the lamp ground wires. Put the rings on the ¼" ground stud, the 2 Awg black
cable will go on top of these.

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Wire the 10 Awg blue/white and green wires to the middle pole strip in the relaybox. Also wire the
smaller cable into the middle pole strip in the relaybox.
Order:
1. 10 Awg Blue/White
2. 10 Awg Green
3. 16 Awg Green/Black
4. 16 Awg Green/White
5. 16 Awg Red/White
6. 16 Awg Brown
7. 16 Awg Blue/White
8. 18 Awg Brown/White
9. 18 Awg Purple
10. 18 Awg White/Black
11. 18 Awg Orange
12. 18 Awg Yellow/Black
13. 18 Awg Black
14. 16 Awg Green
Wire the small gray 22-20 control cable to the 20 pole strip color for
color. Crimp the provided 2 Awg / ¼" hole connectors on the black
and red 2 Awg cables, red goes to the open “BAT” stud on the breaker
and black goes to the ¼" ground stud with the lamp ground wires.
Make sure all wires are tied back so they will not be crushed when the relaybox lid is put on.

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Maintenance
Cleaning
The KNIGHTSLIM 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
ensure years of trouble free service periodically clean all external surfaces with a mild detergent
solution and a gentle spray of water. DO NOT USE A HIGH-PRESSURE WASHER, which will
force water into sensitive electric circuitry.
Lamp lenses may be cleaned with any commercially available glass cleaner.
Upper and lower stage actuators are sealed units and do not require adjustment or lubrication. The
actuators have slip-clutches to compensate for minor stroke tolerances at the limits of its travel. 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 KNIGHTSLIM are self-lubricating thermal polymer. Periodic cleaning with a
moisture displacing cleaner and soft bristle brush, without disassembly, to remove accumulated dirt and
debris will minimize wear.
Center Switch Adjustment
WATCH THE VIDEO AT WWW.COMMANDLIGHT.COM/TECHNICAL-VIDEOS/
Caution: For best results, angle of vehicle should be less than 10 degrees.
1. Raise lower section high enough to comfortably work on, and above the set safety limit
(i.e. Lights will turn on), then raise lamp tree to a 45 degree angle.
2. Visually verify the centering cam on the rotation spindle is contacting the roller of the center
switch arm.
3. Ensure that when the point of the centering cam is aligned with the roller of the center switch
arm, there is some play in the center switch arm. Without this play, the switch could be crushed or
damaged during rotation.
4. Rotate off center, then press the auto park button and let light tower proceed through sequence until
the lamp tree is a couple inches above the nested position, hit emergency stop.
5. Visually determine which side the lamp tree will be hitting the lift arm, then lower lamp tree
completely using the motion switch on the handheld controller.
6. Raise lower section above safety limit and to comfortable working height.
7. Make reference marks with a permanent marker on both sides of the cam.
8. Loosen screw on center switch cam slightly.
9. Tap centering cam toward the side that the lamp tree is hitting the lift arm.
10. Fully tighten the screw holding the center switch cam.
11. Raise lamp tree to a 45 degree angle, rotate off center.
12. Repeat steps 4-9 until satised with centering of the lamp tree.
13. 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 autopark and let it go through the entire sequence.
14. If it is still hitting off center, repeat previous steps.
15. If problems adjusting center still persist you may need to adjust the center switch bracket, or call
Command Light at 1-800-797-7974 for further assistance.

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Notes:
• Making a mark next to the cam on the
bottom of the spindle will make judging the
adjustments much easier.
• Having the lamp tree at either extreme of fully up or down, will affect the degree of
centering. Setting center while the lamp tree at a 45 degree angle produces the best results.
If problems persist, please call Command Light at 1-800-797-7974.
Rotation Belt Adjustment / Tightening
WATCH THE VIDEO AT WWW.COMMANDLIGHT.COM/TECHNICAL-VIDEOS/
1. Raise lamp tree 45º and rotate away from
motor to access rotation motor screws.
2. Remove the (4) screws from the front
midplate cover.
3. Loosen, but do not remove, screws that
retain rotation motor.
4. Using a 1/2" wrench, loosen the jam nut on
the belt tensioner bolt. Using a 3/16" Allen
socket tighten the tensioner bolt to 20 inch
pounds. Tighten the jam nut to lock bolt
in place. Use caution to not over tighten
drive belt. Rotate lamp tree 180 degrees to
verify that belt is not too tight. If belt is too
tight, rotation motor noise level will rise
noticeably.
5. Replace the cover before returning light
tower to active service.
• With the centering cam slightly loose,
it may be easier to adjust its position by
tapping on its edge with the assistance of
a socket driver rather than attempting to
move by hand.