Command Light KNIGHT 2 User manual

3842 Redman Drive 1-800-797-7974
Fort Collins, CO 80524 www.CommandLight.com
MODEL COVERED:
KL409D
Effective March 2020
This guide supersedes all previous versions

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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 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
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Please take the time to read this manual before installing or operating the COMMAND
LIGHT KNIGHT2.
Save this guide for future reference.
Contents
Breakage or Damage During Shipment.......................................................................................................................................... 6
Product Safety Precautions.............................................................................................................................................................. 7
General Description and Specifications.......................................................................................................................................... 7
Operation........................................................................................................................................................................................... 8
Raising the light from the nested position...................................................................................................................................... 9
Returning the light to the nested position .................................................................................................................................... 10
Installation....................................................................................................................................................................................... 10
Installation Kit.............................................................................................................................................................................. 10
Tools Required............................................................................................................................................................................. 11
Installation Notes ......................................................................................................................................................................... 11
Location Requirements ................................................................................................................................................................ 12
Mounting...................................................................................................................................................................................... 13
Holster Mounting......................................................................................................................................................................... 13
Electrical Wiring............................................................................................................................................................................. 14
12 VDC ........................................................................................................................................................................................ 14
Holster Wiring.............................................................................................................................................................................. 14
Warning Device Wiring............................................................................................................................................................... 15
KL409D (KL Slim) Relay Box Wiring........................................................................................................................................ 16
Maintenance .................................................................................................................................................................................... 18
Cleaning ....................................................................................................................................................................................... 18
Center Switch Adjustment ........................................................................................................................................................... 18
Rotation Belt Adjustment............................................................................................................................................................. 19
Power Failure.................................................................................................................................................................................. 20
Rotate to center ............................................................................................................................................................................ 20
Retract the lower stage................................................................................................................................................................. 20
Retract the upper stage................................................................................................................................................................. 21
Troubleshooting .............................................................................................................................................................................. 22
Technical Specifications –Standard DC Models (409D-H4)...................................................................................................... 23
Specifications................................................................................................................................................................................... 25
Parts Lists........................................................................................................................................................................................ 26
Exploded View (Lower Stage)..................................................................................................................................................... 27
Exploded View (Midplate)........................................................................................................................................................... 29
Exploded View (Lamp Tree) ....................................................................................................................................................... 30
Wiring Schematics .......................................................................................................................................................................... 33
Holster Box .................................................................................................................................................................................. 35
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
LIMITED WARRANTY
Five Year
COMMAND LIGHT warrants that the equipment is free from defects in materials and
workmanship when used and operated for a period of five years. The responsibility of COMMAND
LIGHT under this limited warranty is limited to the repair and replacement of any parts found
defective. Parts must be returned to COMMAND LIGHT at 3842 Redman Drive, Ft Collins,
Colorado 80524 with transportation charges prepaid (C.O.D. shipments will not be accepted).
Prior to returning defective parts to COMMAND LIGHT, the original purchaser shall make a
claim in writing to COMMAND LIGHT at the above address indicating the model number, serial
number and type of defect. No parts or equipment will be received by COMMAND LIGHT for
repair or replacement under this warranty without specific written authority from it in advance.
Any parts damaged by improper installation, overloading, abuse or accident of any type or cause
are not covered by this warranty.
All equipment manufactured by us is tested before leaving our plant, and is shipped in good
working order and condition. We therefore extend to the original purchasers the following Limited
Warranty for the period of five years from the original date of purchase:
1. This warranty does not apply to defects caused by accident, misuse, neglect, or wear and tear,
nor can we be held responsible for incidental and consequential expense and loss, nor does this
warranty apply to equipment where alterations have been executed without our knowledge or
consent. These conditions are readily discernible when the equipment is returned to us for
inspection.
2. On all component parts not manufactured by COMMAND LIGHT, their warranty is to the extent
that the manufacturer of such component warrants them to COMMAND LIGHT, if at all. Look
in your local business telephone directory for the nearest repair station for the brand of parts you
have or write to us for the address.
3. If equipment received has been damaged in transit, a claim should be made against the carrier
within three days, as we assume no responsibility for such damage.
4. Any service other than our Authorized Service voids this warranty.
5. This warranty is in lieu of and is intended to exclude all other warranties, express or implied, oral
or written, including any warranties of MERCHANTIBILITY or FITNESS for a particular
purpose.
6. Travel time paid at a maximum of 50% and only if pre-approved.

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

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Product Safety Precautions
Never operate the COMMAND
LIGHT KNIGHT2near overhead
high voltage power lines. The
COMMAND LIGHT KNIGHT2 is
manufactured from electrically
conductive materials.
Do not use the COMMAND
LIGHT KNIGHT2 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 KNIGHT2 as a lifting device or mobile arm.
Do not use a COMMAND LIGHT KNIGHT2 that has been damaged or is not fully
functional, including non-working indicator lamps.
Never hold any part of the COMMAND LIGHT KNIGHT2with a hand or foot
while it is in motion.
The COMMAND LIGHT KNIGHT2 has numerous pinch points. Keep loose
clothing, hands and feet clear of moving parts.

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General Description and Specifications
The KNIGHT2is 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 KNIGHT2near overhead power lines.
There are several standard lighting options available for the KNIGHT2.
The emergency vehicle generator provides power for the 12 VDC circuitry. The umbilical
corded control unit is powered via 12 VDC eliminating hazardous voltage levels within the
hand held control box.
The KNIGHT2is manufactured to provide years of service with a minimum of maintenance.
Model #
Description
Minimum Power Requirements
KL409D-H4
4 x LED
100 Amps, 12 VDC
Identification 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 KNIGHT2has an override system that precludes rotation of the upper stage until the
lower stage has elevated approximately 16” from the nested position. When the lower stage
is below 16” the following conditions exist:
•Upper stage is prevented from rotating.
•All lights are turned off, including strobe light if equipped, regardless of light switch
positions.
•Prevents the upper stage from moving down if upper stage is not centered.
If the supply from the generator is marginal, position the KNIGHT2 before turning on lights.

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Returning the light to the nested position
The KNIGHT2is equipped with an Autopark function as a standard feature. The green
button on the control box initiates the Autopark sequence. Once initiated, the “Emergency
Stop” red button indicator is illuminated. Pressing the “Emergency Stop” button will cancel
the Autopark sequence.
Autopark Sequence
Press green button on the controller once. It does not need to be held in position. The
Autopark sequence begins:
1. “Emergency Stop” light is illuminated.
2. Lamps are extinguished.
3. Upper stage begins rotation to the center position.
4. Once upper stage is centered, rotation stops, lower stage begins retracting.
5. After lower stage has fully retracted, upper stage begins retracting. Upon upper stage
retracting fully, “Emergency Stop” light turns off.
Installation
The KNIGHT2must 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 KNIGHT2is an installation kit. Verify that the kit contains the following
items:
(1) 50 feet of 2GA-2 Conductor power cable (1) 50 feet of 22GA-20 conductor cable
(1) Pre-wired HOLSTER BOX w/cover (1) Handheld Controller
(1) Small hardware parts bag with:
(4) mounting spacers (4) 5∕16-18 x 2 ½” bolts
(4) 5∕16-18 nylon lock nuts (8) 5∕16” flat washers
(4) large diameter flat washers (2) ¼-20 x 5∕8” Phillips flat head machine screws
(2) ¼” flat washers (2) ¼-20 nylon lock nuts
(4) ½” 90° sealing connector w/nut (1) 1” 90° sealing connector w/nut

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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 flat blade screwdriver (included with light)
7/16”and 1/2”combination wrenches and/or ratchet and 7/16”and 1/2”sockets
8” adjustable wrench
Tongue and Groove Pliers
Wire stripper or razor blade knife
Solder-less wire connector crimp tool
Silicone based gasket sealer, RTV™ recommended
Installation Notes
The KNIGHT2weighs approximately 150 pounds. Use mechanical assistance to lift the
light into installation position such as a forklift or crane.
Use the provided fender washers under the mounting surface to distribute the weight load
evenly.
When routing the connecting electrical wires take care to avoid sharp bends, hot
components or other hazards to the wire.
The KNIGHT2is not designed to be operated in a raised position while the vehicle is in
motion. The KNIGHT2includes warning circuit wiring to enable a warning device.

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Location Requirements
The standard KNIGHT2Model 409D can be mounted on any location that is 50” x 13”. The
surface should be flat or have only a slight crown. For a recessed installation allow for a
minimum of 60” x 20”. Consult with factory before construction of recessed installation.
Verify all dimensions before installation to ensure proper operation of light will not infringe
on other installed components. For all other installations refer to the dimensional drawing
included in the back of this guide that represents your particular model of light. The
drawings reflect the dimensions of the “working envelope” of a typical light tower. Make
certain sufficient clearances are incorporated in your installation to allow for variations
(vehicle body flex, environmental conditions, future servicing needs, etc.) If your light is not
represented, call the factory prior to beginning any construction of a recessed installation.
Four mounting bolt holes are required. Additional holes may be drilled in the frame ends if
necessary to clear obstructions.
Access holes for the power cord cabling should be in close proximity to the 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.
RECOMMENDED AREA
FOR CABLES

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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 KNIGHT2. The center of gravity (balance
point) is slightly behind the lower bank of lights.
Slowly lift the KNIGHT2and check for balanced lifting. Lower and make any necessary
adjustments to the lift points.
Lift and place the KNIGHT2into position above the spacers. Before placing the full weight
of the unit on the spacers align spacers with the holes in the end frame castings.
Drill 21/64” holes in the mounting surface using
the end casting holes as a template.
Fasten the light using the provided hardware.
To ensure a weather-tight installation apply a
thin bead of silicone based gasket sealer to the
base of the spacer and underside of bolt head.
Remove any lifting straps and devices from the
KNIGHT2.
Locate and drill the wire feed holes.
Holster Mounting
Using the holster mount as a template, mark
hole locations.
Drill 17/64” mounting holes.
Drill any holes required to route the control cable from the holster to the KNIGHT2relay
box. Attach the holster to the holster mount with the provided hardware.

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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 KNIGHT2.
Run the power wire from the breaker box or generator to the KNIGHT2. A 100 Amp
breaker is recommended on DC models.
Make the control connections in the KNIGHT2 relay box.
The Model KL409D series KNIGHT2comes pre-wired to connect to 12 VDC.
12 VDC
Holster Wiring
Determine if an elevated warning device will be used in conjunction with the light tower. If
a warning device will be used, use the wiring diagram on the next page, otherwise, use the
wiring diagram in the back of the user guide.
After routing the control cable into the holster through the sealing connector, attach
individual wires to the provided connectors and insert the connectors into the proper ports
on the circuit board

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

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KL409D (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 KNIGHT2is constructed with corrosion resistant aluminum and stainless steel
fasteners. To further enhance corrosion resistance all exposed surfaces receive a powder
coated paint finish. To ensure years of trouble free service periodically clean all external
surfaces with a mild detergent solution and a gentle spray of water. DO NOT USE A
HIGH-PRESSURE WASHER, which will force water into sensitive electric circuitry.
Lamp lenses may be cleaned with any commercially available glass cleaner.
Upper and lower stage actuators are sealed units and do not require adjustment or
lubrication. The actuators have slip-clutches to compensate for minor stroke tolerances at
the limits of its travel as well as internal limit switches. The actuator may produce a
ratcheting sound at each end of the stroke which is normal. The actuators should not be
made to ratchet excessively, this can lead to premature actuator clutch failure.
All pivot points on the KNIGHT2are 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
Caution: For best results, angle of vehicle should be less than 15 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. Loosen screw on center switch cam slightly.
8. Tap centering cam toward the side that the lamp tree is hitting the lift arm.
9. Fully tighten the screw holding the center switch cam.
10. Raise lamp tree to a 45 degree angle, rotate off center.
11. Repeat steps 4-9 until satisfied with centering of the lamp tree.
12. 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.
13. If it is still hitting off center, repeat previous steps.
14. 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.
•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.
•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
1. Raise lamp tree to permit easy access.
2. Remove the (6) screws from the 2-piece midplate cover.
3. Remove the (4) screws that retains the midplate surround cover. Rotate the cover up and
away from the main lift arm, around the pivot point.
4. Lower lamp tree fully and rotate away from motor to access rotation motor screws.
5. Loosen, but do not remove, screws that retain rotation motor.
6. Make sure both pulleys are parallel and in alignment with each other. To adjust any
misalignment loosen the (2) set screws securing the small drive pulley to motor shaft.
Adjust as required and tighten set screws.
7. Belt should fit snugly, neither too loose nor too tight. Avoid any preload, which can cause
premature failure.
8. Using a suitable pry bar, apply gentle pressure between rotation motor case and sheet
metal motor mount. Use caution to not over tighten drive belt. 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.
9. Replace all covers before returning light tower to active service.

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Power Failure
The KNIGHT2can 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 KNIGHT2before manual operation.
Rotate to center
Locate the belly plate on the bottom of the lift arm and remove it by loosening all 4 screws
and only removing 2 of them. Disconnect the Red/White and Brown wires from one side of
the connecting terminals using a small flat blade screw driver.
Slowly apply pressure to the lamp tree to manually rotate to the centered position. Trying to
rotate too quickly or with too much pressure can break the rotation motor shaft. Be certain
that you rotate in the proper direction; the upper stage can rotate a full 360˚. Generally, you
need to rotate the lamp tree in the direction that requires the least amount of travel in order
to reach a centered position. If manual rotation causes the rotation belt to slip, this is alright
if minimized. Excessive slippage on the belt may cause enough damage for the need of belt
replacement.
Retract the lower stage
Slowly apply pressure to the rotation platform to manually rotate to the centered position.
Trying to rotate the platform too quickly or with too much pressure can break the rotation
motor shaft or cause the toothed drive belt to shear a tooth. The upper stage can be rotated in
either direction.
Generally, you need to rotate the platform in the direction that requires the least amount of
travel in order to center the platform.
Support the midplate assembly with temporary blocking to relieve the tension on the lower
actuator pivot pins.
Using a small flat blade screw
driver, remove the retaining rings
that secure the lower pivot pin in
place. New retaining rings must be
installed before returning light to
service.
Use a brass drift punch to remove
the pivot pin from the extension end
of the actuator. Avoid using a
hardened steel punch which could peen the end of the shaft thus damaging the bore within
the aluminum pivot blocks.