Command Light KNIGHT KL415A User manual

Eective September 2020
is guide supersedes all previous versions
MODEL COVERED:
KL415A
3842 Redman Drive
Fort Collins, CO 80524
1-800-797-7974
www.CommandLight.com
KNIGHT SERIES

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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.
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
Warranty..................................................................................................................................................... 5
Warranty/Service ................................................................................................................................ 6
Breakage or Damage During Shipment ................................................................................................... 7
Product Safety Precautions ....................................................................................................................... 8
General Description and Specications ................................................................................................... 9
Operation.................................................................................................................................................. 10
Raising the light from the nested position........................................................................................ 10
Returning the light to the nested position......................................................................................... 11
Installation................................................................................................................................................ 12
Installation Kit.................................................................................................................................. 12
Tools Required.................................................................................................................................. 12
Installation Notes.............................................................................................................................. 12
Location Requirements..................................................................................................................... 13
Mounting .......................................................................................................................................... 14
Holster Mounting.............................................................................................................................. 14
Electrical Wiring ...................................................................................................................................... 15
12 VDC............................................................................................................................................. 15
Holster Wiring .................................................................................................................................. 15
Warning Device Installation ............................................................................................................. 16
Maintenance ............................................................................................................................................. 17
Cleaning............................................................................................................................................ 17
Center Switch Adjustment................................................................................................................ 17
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
Technical Specications – Standard DC Models (408D) ...................................................................... 23
Specications.................................................................................................................................... 24
Parts Lists - Exploded Views................................................................................................................... 25
Exploded View (Base) .................................................................................................................25-26
Exploded View (Midplate) .......................................................................................................... 27-28
Exploded View (Lamp Tree) .......................................................................................................29-32
Relay Box ....................................................................................................................................33-34
Wiring Schematics ................................................................................................................................... 35
Relay Box ......................................................................................................................................... 36
Holster Box..................................................................................................................................37-38
Dual Controls (VMUX/Wireless Systems) ...................................................................................... 39
Lamp Tree......................................................................................................................................... 40

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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 ve 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 specic 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 ve 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 ve 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!

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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 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
KNIGHT2near overhead high voltage power
lines. The COMMAND LIGHT KNIGHT2is
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 KNIGHT2as a lifting device or mobile arm.
[Do not use a COMMAND LIGHT KNIGHT2that has been damaged or is not fully functional,
including non-working indicator lamps.
[Never hold any part of the COMMAND LIGHT KNIGHT2 with a hand or foot while it is
in motion.
[The COMMAND LIGHT KNIGHT2has numerous pinch points. Keep loose clothing,
hands and feet clear of moving parts.

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General Description and Specications
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.
ere are several standard lighting options available for the KNIGHT2.
Model # Description Minimum Power Requirements
KL415A 6 x LED 2 kW Generator, 110 or 240 VAC
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 KNIGHT2 is manufactured to provide years of service with a minimum of maintenance.

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Operation
Raising the light from the nested position
Using the control box, raise the lower or upper stage. You may also activate both stages simultaneously.
Control switches are of momentary action style and must be held in the “on” position to actuate the
stages.
The 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 KNIGHT2before 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. 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.

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Installation
The KNIGHT2 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 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” 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
(3) 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 KNIGHT2weighs 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 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 KNIGHT2Models 415A can be mounted on any location that is 47” x 23”. The surface
should be at or have only a slight crown. For a recessed installation allow for a minimum of 58” x
29”. 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 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 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 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 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 20 Amp breaker is
recommended on AC models with LED xtures.
Make the control connections in the KNIGHT2relay box.
The standard model KL415A series KNIGHT2comes pre-wired to connect to 120 VAC. It is necessary
to remove the jumper connecting the red and black terminals for 240 VAC operation.
Holster Wiring
Determine if an elevated warning device will be used in conjunction with the light tower. If a warning
device will be used, use the wiring diagram on the next page, otherwise, use the wiring diagram in the
back of the user guide.
After routing the control cable into the holster through the sealing connector, attach individual wires to
the provided connectors and insert the connectors into the proper ports on the circuit board.
120 VAC 240 VAC
If 240 VAC operation is desired, remove the
jumper wire between the red and black leads.
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.

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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.
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.

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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 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 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
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 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 t snugly, neither too loose nor too tight. Avoid any preload, which can cause
premature failure.
8. Using a suitable pry bar and a wood or polymer block/spacer, 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.
• 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.

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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.
WATCH THE VIDEO AT WWW.COMMANDLIGHT.COM/TECHNICAL-VIDEOS/
Retract the Upper stage
Locate the black, plastic literature canister mounted
to the side of the base of the tower, it contains a
90-degree 3/16 allen wrench and a 3/8th drive ¼” allen
socket.
Use the 90-degree allen wrench to remove the outer
cover screw on the upper actuator.
Insert the ¼” socket into drive socket in the actuator
gear box and rotate clockwise to retract the ram until
lamp tree is fully lowered.
Replace the cover screw! The actuator may become
damaged if the cover screw is not replaced.
Rotate to Center
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
Using the same allen tools as before, remove the cover
screw and retract the ram of the actuator as
far as possible for safe travel back to station or
repair facility.
Be careful not to hit the lower lamps on main electrical
box if your tower has the Backlight option and the lamps are not ush with the xed lamps.
If needed the Backlight may be rotated back to the home position where it is ush with the xed lamps.
Slowly apply pressure to the Backlight lamps to manually rotate to the home position. Trying to rotate
too quickly or with too much pressure can break the Backlight motor shaft.
Replace the cover screw on the actuator!

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IN THE EVENT THAT ALLEN WRENCHES FOR LOWERING THE TOWER CANNOT BE
FOUND THE TOWER MUST BE LOWERED BY REMOVING THE ACTUATOR MOUNT PINS:
Rotate to center without the lowering tools
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.
Retract the lower stage without the lowering tools
Support the Midplate (rotation) assembly with temporary blocking to relieve the tension on the lower
actuator pivot pins.
Using a small at blade screwdriver or needle-nose pliers,
remove the retaining rings that secure the lower pivot pin
in place.
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.
Note that the light weighs in excess of 100 pounds, use caution.
Apply upward pressure on the main lift arm to remove support blocking then slowly lower the lift arm
allowing the actuator shaft to extend past the lower pivot blocks.
Retract the upper stage without the lowering tools
Support the lamp tree with temporary blocking to relieve the tension on the upper actuator pivot pins.
Using a small at blade screwdriver or needle-nose pliers, remove the 4 e-clips securing the lower pin
of the upper actuator.
Support the lamp tree. Depending on conguration, the weight
of the lamp tree may exceed 50 lbs. Use a brass drift to remove
the pin.
Lift up on lamp tree to remove support blocking. Rotate the
actuator towards the front of the light. The upper stage will not
be completely lowered but should provide ample clearance to
transport the light.
Cushion and secure the actuators and other components as
necessary before transporting.
New retaining rings must be installed before returning light
to service.