BUILD INFORMATION SERIAL #: MODEL #: DEALER: DESTINATION: OPTIONS: NOTES: DESCRIPTION Lights COMPLETED NOTES Strobe (Optional) Set Screws Wires Tied Neatly Lower Actuator Lamp Mount Bolts Rubber Feet Decal Harnesses Tighten Relay Board Stamp Serial # Clean Clear Acrylic Relay Box Controller Holster Sealcons Tight Inspection Completed By (Initials) Date: www.commandlight.com
SS335 Model: SS335 PO BOX 87 LOVELAND, CO 80539 PHONE: 1-800-797-7974 FAX: 1-970-667-4296 WEB: www.commandlight.com This document supersedes all previous documents. Effective Tuesday, July 07, 2009
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. PO BOX 87 LOVELAND, CO 80539 PHONE: 1-800-797-7974 FAX: 1-970-667-4296 WEB: www.commandlight.com
PERSONAL RESPONSIBILITY CODE The member companies of FEMSA that provide emergency response equipment and services want responders to know and understand the following: 1. Firefighting and Emergency Response are inherently dangerous activities requiring proper training in their hazards and the use of extreme caution at all times. 2. It is your responsibility to read and understand any user s instructions, including purpose and limitations, provided with any piece of equipment you may be called upon to use. 3. It is your responsibility to know that you have been properly trained in Firefighting and/or Emergency Response and in the use, precautions, and care of any equipment you may be called upon to use. 4. It is your responsibility to be in proper physical condition and to maintain the personal skill level required to operate any equipment you may be called upon to use. 5. It is your responsibility to know that your equipment is in operable condition and has been maintained in accordance with the manufacturer s instructions. 6. Failure to follow these guidelines may result in death, burns or other severe injury. Fire and Emergency Manufacturers and Services Association, Inc. P.O. Box 147, Lynnfield, MA 01940 www.femsa.org Copyright 2006 FEMSA. All Rights Reserved
Straight Shadow SS335 TABLE OF CONTENTS USER GUIDE Safety Precautions 1 Breakage or Damage During Shipment 2 Common Replacement Parts 3 Installation Requirements 4 Mounting Instructions 5 Electrical Wiring Installation 6 Operating Instructions 7 Troubleshooting Guide 8 Technical Specifications 9 Maintenance a. Parts Replacement i. Light Bulb 10 ii. Actuator 13 iii. Actuator stuck in retracted position 20 b. Cleaning 23 Limited Warranty 26 Appendix: Wiring Diagram Parts List
Straight Shadow SS335 1 PRODUCT SAFETY PRECAUTIONS Never operate the near overhead high voltage power lines. The is manufactured from electrically conductive materials. Do not use the COMMAND LIGHT for uses other than its intended purpose. Do not move emergency vehicle with the light extended. Visually verify that the light is completely nested before moving vehicle. Do not change light position while people are located within its operating envelope. There are numerous pinch points that can cause serious bodily injury. Do not use a high-pressure washer or subject the light to high volumes of water when cleaning. Never use the as a lifting device or mobile arm. Do not use a that has been damaged or is not fully functional, including non-working indicator lamps. Never hold any part of the with a hand or foot while it is in motion. The has numerous pinch points. Keep loose clothing, hands and feet clear of moving parts.
Straight Shadow SS335 2 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.
Straight Shadow SS335 3 COMMON REPLACEMENT PARTS Part Number Description 065-12850 500 Watt, 120 V, Lumenform Bulb 065-14175 150 Watt, 120 V, FRC Optimum Bulb 069-15384 6 inch, Actuator, 12 V, Bear Linear
Straight Shadow SS335 4 INSTALLATION REQUIREMENTS The SHADOW must be installed through a designated facility by qualified personnel only. All safety precautions must be thoroughly understood before installation. Please consult the factory for additional installation information or assistance. Refer to the drawing below to determine the location of the required (4) mounting hole locations. The SHADOW weighs 35-45 pounds depending on the options installed. Use assistance to lift the light into position. Drill (4) 17/64 holes to secure the device to vehicle. Remove any obstructions below the mounting surface such as headliners. Fasten the light using the provided hardware. When routing the connecting electric wires use care to avoid sharp bends, hot surfaces or other hazards to the wire. In. [mm] In. [mm]
Straight Shadow SS335 5 MOUNTING INSTRUCTIONS Place the SHADOW in the desired mounting position on the vehicle. Mark and drill the four (4) mounting holes with a 17/64 drill. Clean mounting holes, apply bead of silicone sealant around holes. Mount Shadow using the provided ¼-20 x 1-1/4 hex head cap screw and ¼ flat washer from above. Secure from below with ¼ fender washer and ¼-20 lock nut. Remove the controller and controller pocket from the face of the black holster box. Place holster box in desired location on the vehicle. Mark and drill two (2) 17/64 mounting holes. Mount holster using provided ¼-20 x 5/8 PHP machine screws, washers, and nuts.
Straight Shadow SS335 6 ELECTRICAL WIRING INSTALLATION The SHADOW is supplied with three (3) cables with connectors attached. The black SJOOW 12/3 cable supplies the SHADOW with AC current from the vehicle generator. The gray PVC 18/12 cable supplies the SHADOW control circuit. The 12-2 cable provides 12VDC to the holster. Cables are intended to route down through the roof of the vehicle from the SHADOW. Drill two (2) 7/8 holes through the roof of the vehicle near the SHADOW. The holes will accommodate the two (2) provided 90 degree Sealcon connectors. Mount the connectors through the roof with silicone sealant first. Secure with nuts from below. Route the cables down through the Sealcons, attach the connectors at the ends of the cables to the corresponding panel mount on the SHADOW. Allow enough cable above the roofline so as not to stretch the cables. Lock down the 90 degree Sealcons. Route the AC cable to the vehicle breaker panel. Breaker the supply at 20 amps. Wire BLACK to 120V AC, WHITE to NEUTRAL, and GREEN to GROUND. Route the DC and control cable down and into the straight Sealcon on the holster box. Route the 12-2 DC cable to battery or 12V DC power to holster. Wire the conductors into the top side of the 8-pole barrier strip as follows: Right Pole Function Left BLUE 1 Right Lamp BLUE RED 2 Center Lamp RED BLACK 3 Left Lamp BLACK ORANGE/BLACK 4 Actuator DOWN ORANGE/BLACK RED/BLACK 5 Actuator UP RED/BLACK WHITE/BLACK JMP 6 12 VDC (+) Control BLACK/WHITE CONTROLLER GREEN & 7-12 VDC WHITE 12 AWG WIRE (-) FROM GREEN/BLACK WHITE & WHITE/BLACK 12 VDC GROUND 8 +12 VDC BLACK 12 AWG WIRE (+) FROM 12 VDC SOURCE
Straight Shadow SS335 7 OPERATING INSTRUCTIONS 1. Make sure the area around the Shadow is clear of tree limbs, low hanging wires, or other obstacles that may interfere with its operation. 2. By placing the switch on the control panel labeled UP/DOWN in the up or down position the light will extend or retract. 3. To illuminate the lights push the upper switches into the up position. Each set of lights has a corresponding switch. It is possible to use only some of the lights depending on the amount of light needed and the model. 4. Remember to turn off all lights when finished. CAUTION: Once the light is fully extended or retracted DO NOT continue to activate the up/down switch. This will put unnecessary pressure on the actuator and could lead to actuator failure.
Straight Shadow SS335 8 Trouble Shooting Guide Problem Possible Reason Possible Solution Will not raise Loss of 12V Power Check continuity of Blue & White wires in Control Holster All lights will not illuminate 1 or 2 lights will not illuminate Actuator makes ratcheting noise Bad Actuator No A/C Power Bulbs Burnt out Failed Relay Normal Clutch Operation Check DC power source See actuator replacement guide in manual Check incoming A/C power source See Bulb replacement guide in manual Call Command Light This sound is normal when the actuator has reached the end of its range. DO NOT CONTINUE TO HOLD RAISE OR LOWER FUNCTION IN ON POSITION FOR ALL OTHER PROBLEMS OR CONCERNS CALL AT 1-800- 797-7974 OR 1-970-667-5146
Straight Shadow SS335 9 TECHNICAL SPECIFICATIONS
Straight Shadow SS335 10 MAINTENANCE BULB REPLACEMENT Model: SS325/335/345 Tools required: #2 Phillips head screw driver 5/32 hex driver Clean oil-free cloth Cleaning alcohol Position lamp tree so lamps are readily accessible. Disconnect the power supply from the SHADOW. Allow sufficient time for the lamps to cool. The surrounding metal lamp housings can cause serious burns. Grasp the lamp lens bezel firmly, remove the screw that holds the lamp bezel in place. Use caution, the lamp bezel and lens may fall if not properly grasped. Caution: be certain that the lamp is cool to the touch before handling. Do not touch the lamp directly. Use a clean oil-free towel to handle the lamp. The lamps operate at high temperatures. Handling the lamps directly leaves minute traces of skin oils that cause localized hot spots that can lead to early lamp failure. Lamp surfaces may be cleaned with alcohol. Latch the bezel making sure that the weather stripping is properly fitted.
Straight Shadow SS335 11 FRC OPTIMUM METAL HALLIDE LAMP (75w 150w) STEP 1: Using your 5/32 hex driver, remove all 4 hex screws STEP 2: Using a small flat head screwdriver, gently lift up one corner of the glass and remove. (Be careful not to use to much pressure) STEP 3: Push the bulb in to your right, pull left corner out and remove.!!! IMPORTANT REMINDER NOTES!!! 1. Make sure when handling new lamp replacement that all oil, residue, and contaminants are wiped away before operating. *(Failure to do so could result in premature bulb failure or decrease life expectancy) 2. Make sure both contact pins are in the grooves of new lamp. 3. Make sure when putting glass shield back in place that all edges are touching the rubber seal. When tightening hex screws, make sure they are tightened snuggly to ensure all weather does not enter light fixture.
Straight Shadow SS335 12 LUMINFORM LIGHT REPLACEMENT (500w) STEP 1: Loosen top screw with #2 Phillips screw driver STEP 2: Pushing the bulb to your right, pull the left corner out and remove!!! IMPORTANT REMINDER NOTICE!!! 1. Make sure when handling new bulb replacement that all oil, residue, and contaminants are wipe away before operating. 2. Tighten top screw so that the front face is tight against rubber seal
Straight Shadow SS335 13 ACTUATOR REPLACEMENT Model: SS322, SS325, SS335, SS345, SS380 Tools Required: 1/8 hex key driver #2 Phillips head screw driver 1/8 Flat head screwdriver Hammer Drift Punch Position lamp tree so it is raised just over 90 degrees. Disconnect the power supply from the SHADOW. STEP 1: Using the 1/8 hex key driver, loosen the top set screw. STEP 2: Using the 1/8 hex key driver, loosen the bottom set screw.
Straight Shadow SS335 14 STEP 3: Using your drift punch and hammer, knock out the top pin holding the actuator. *(After knocking out pin be sure to hold the lamp tree and slowly lean it forward till it stops at its resting point) STEP 4: Repeat the same process in step 3 for the bottom pin STEP 5: Using your #2 Phillips head screw driver, remove the 4 screws securing the cover plate behind the actuator
Straight Shadow SS335 15 STEP 6: After removing the cover plate, locate the orange/black and red/black wires. With your 1/8 Flat head screwdriver, loosen the 2 flat head screws securing them to the 20 pole strip and remove them. STEP 7: Loosen Connect all and pull actuator wires out STEP 8: Put new actuator in place and push wires back through connect all. *(Taping the ends of the wires with electrical tape will help prevent damage to the end of wires.)
Straight Shadow SS335 16 STEP 9: Remove tape from the end of wires and connect them back to the 20 pole strip. STEP 10: Tighten connect all back up and make sure there is enough slack for actuator to fully extend properly without straining the wires.
Straight Shadow SS335 17 STEP 11: Take the bottom pin for actuator and apply some copper based anti-seize then insert the pin back in place. STEP 12: Take the top pin for actuator and apply some copper based anti-seize then insert the pin back in place
Straight Shadow SS335 18 STEP 13: Tighten both top and bottom set screws to secure top and bottom actuator pins. STEP 14: Put cover plate back in place lining all 4 holes up with corners.
Straight Shadow SS335 19 STEP 15: Apply a light layer of medium strength thread locker to all 4 screws and tighten the cover plate back down. *(Make sure that no screws, parts or debris has fallen into wire box before you secure the wire box cover back down.)
Straight Shadow SS335 20 ACTUATOR REPLACEMENT (When Shadow is in retracted position) The following instructions are for replacing the actuator on a Shadow when it is stuck in the retracted (closed/lowered) position. The preferable method of replacing an actuator is to access it when the device is in the extended (raised) position. However, when the actuator has failed this is not always possible. Step One Remove Rod Fasteners Using a 1/8 hex wrench remove fastening pins from both sides of the rotation rod. Step Two Remove Rotation Rod Using a flat punch or rod and a hammer, remove the rotation rod. It may be necessary to apply significant force to remove the rod. However, care should be taken to make sure force is applied only to the rod end and not to other parts of the unit.
Straight Shadow SS335 21 Step Three Access the Actuator By carefully lifting the upper arm off of the assembly, position the arm so that the actuator can be accessed. It may be helpful to place a block of wood under the upper arm to hold it in position while maintenance on the actuator is performed. Step Four Remove Fastener Pins from both Actuator Rods Using a 1/8 hex wrench remove the fastener pins from both actuator rods. The upper arm may need to be moved to effectively access the pins. Upper Rod Pin Lower Rod Pin
Straight Shadow SS335 22 Step Five Remove Actuator Rods Similar to the process in step two, use a flat punch and a hammer to remove both actuator rods. Once again, care should be taken to make sure force is applied only to the rod end and not to other parts of the unit.
Straight Shadow SS335 23 CLEANING The SHADOW is constructed with corrosion resistant aluminum and stainless steel fasteners. To further enhance corrosion resistance all exposed surfaces receive a powder coated paint finish. To assure years of trouble free service periodically clean all external surfaces with a mild detergents 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 commercially available glass cleaner. Actuator is a sealed unit and does not require adjustment or lubrication Periodic cleaning of all pivot points on the SHADOW with moisture displacing cleaner and a soft bristle brush, without disassembly, to remove accumulated dirt and debris will minimize wear. WHAT TO LOOK FOR IN DIRT BUILD UP ON PIVOT POINTS Excessive dirt stuck inside, around, on top, or anywhere near the TOP or BOTTOM of the pivot point.
Straight Shadow SS335 24 PIVOT POINT CLEANING PROCEDURES STEP 1: Open and extend light tree till it is open about 90 degrees. This allows sufficient room to wipe and clean properly. Take a regular shop rag or towel and wipe away heavy surface dirt from the Top and bottom pivot points first. STEP 2: With your moisture displacing cleanser, spray the top and bottom pivot points.
Straight Shadow SS335 25 STEP 3: After letting them soak for approximately 15 seconds, take you soft bristled brush and clean away remaining dirt. *(Repeat these steps as necessary till pivot points are clean and free from dirt.)!!! IMPORTANT REMINDER!!! 1. How often the cleaning procedures on pivot points are going to have to be performed is going to differ upon the applications and conditions the unit is being used under. 2. To prevent premature wear or improper working of parts, regular inspection is strongly recommended.
Straight Shadow SS335 26 Command Light PHONE: 1-800-797-7974 P.O. Box 87 FAX: 1-970-667-4296 Loveland, CO 80539 WEB: www.commandlight.com Limited Warranty Five Year 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 under this limited warranty is limited to the repair and replacement of any parts found defective. Parts must be returned to at 1303 East 11 th Street, Loveland, Colorado 80537 with transportation charges prepaid (C.O.D. shipments will not be accepted). Prior to returning defective parts to, the original purchaser shall make a claim in writing to at the above address indicating the model number, serial number and type of defect. No parts or equipment will be received by for repair or replacement under this warranty without specific written authority from it in advance. Any parts damaged by improper installation, overloading, abuse or accident of any type or cause are not covered by this warranty. All equipment manufactured by us is tested before leaving our plant, and is shipped in good working order and condition. We therefore extend to the original purchasers the following Limited Warranty for the period of five years from the original date of purchase: 1. This warranty does not apply to defects caused by accident, misuse, neglect, or wear and tear, nor can we be held responsible for incidental and consequential expense and loss, nor does this warranty apply to equipment where alterations have been executed without our knowledge or consent. These conditions are readily discernable when the equipment is returned to us for inspection. 2. On all component parts not manufactured by, their warranty is to the extent that the manufacturer of such component warrants them to, 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.
9 3 4 16 14 10 11 15 7 6 19 1 8 5 17 18 13 2 Parts List ITEM QTY PART NUMBER DESCRIPTION 1 4 PHPMS-05 6-32 UNC x 3/8 PHP MS SS 2 4 065-12846 BOOT,TOGGLE SWITCH,BLACK,C1131/35-20 3 1 065-13010 SEALCON, STRAIN RELIEF, 3/8 4 1 065-12888 CABLE, 22-12, COIL, CONTROLLER 5 1 065-13015 STRAIN RELIEF, 1/2, 90 DEG, BLK GROMMET 6 3 065-13014 LOCKNUT, 1/2, STRAIN RELIEF 7 2 065-13009 STRAIN RELIEF, 1/2, T&B, BLACK GROMMET 8 1 065-13044 PLUG,FINISHING,1.0625 9 1 075-00711 BOX,HOLSTER,CONTROLLER,ALL 10 1 065-12868 GROMMET, 1/16, BLACK, CL MIDPLATE 11 1 065-14802 STRIP, BARRIER, 8 POLE 12 1 065-12921 DECAL, CAUTION HIGH VOLTAGE, YELLOW 13 1 075-11084 HOLSTER,WELDMENT,SSxxx 14 1 065-12845 SWITCH, TOGGLE, ON-OFF-ON, CARLING 15 6 065-12490 TERMINAL #68202 18-22 GA RED F.Q.D..250 16 3 065-12515 TERMINAL, 18-22, #6 FORK 17 1 065-12876 BOX,CONTROL,UNFINISHED,SHADOW 18 1 069-15375 FACEPLATE, BLACK ENGRAVED, SS335 19 3 065-12844 SWITCH, TOGGLE, ON-OFF, TAB SS 335 Hand Control
4 3 7 6 8 5 2 10 Parts List ITEM QTY PART NUMBER DESCRIPTION 1 1 078-11101W TREE,LAMP,3 HEAD,SL3xx 2 6 LNUT-06 Nut, Nylock, 1/4-20 UNC 3 6 HNUT-10 1/4-20 x 1-3/4 Hex Head Cap Screw SS 4 3 069-15332R2 Crouse-Hinds Lamp Head 500W 5 4 PHPMS-26 8-32 UNC x 3/4 PHP MS SS 6 4 LNUT-04 Nut, Nylock, 8-32 UNC 7 3 078-11095 STANDOFF, LAMP, SHADOW 8 3 065-12815 STRAIN RELIEF, 90 DEG, ALUM 9 3 065-12971 LOCKNUT, 3/8, STRAIN RELIEF 10 2 024-10527 PAD, 1/2 X 1 X 2, RUBBER SS 335 Lamp Tree 1
7 21 8 7 11 6 5 28 5 17 4 6 3 26 14 Parts List ITEM QTY PART NUMBER DESCRIPTION 4 1 065-13007 STRAIN RELIEF, 1/2, T&B, BLACK GROMMET 5 4 065-13009 STRAIN RELIEF, 1/2, T&B, BLACK GROMMET 6 4 065-13014 LOCKNUT, 1/2, STRAIN RELIEF 3 1 065-13017 LOCKNUT, 3/4, STRAIN RELIEF 17 1 069-12890 STRIP, BARRIER, 20 POLE 2 1 078-11001W BASE,SHADOW,WELDME NT 7 2 078-11056 PIN, ACTUATOR, SHADOW SL3xx 8 1 078-11057 PIN, MAIN, PIVOT, SHADOW SL3xx 11 1 078-11060 COVER, RELAY, SHADOW SL3xx 14 1 078-12000A CONTROL,RELAYS,SHAD OW SSxxx 15 2 91771A245 FHMS, Phillips, 10-24 UNC x 3/4 in 21 1 Actuator_6_Inch_90 Actuator, D12-21B5-06HC, 6 INCH, 12V 16 4 FWASH-10 Washer, Flat, USS, #10, SS 26 1 069-14249 BLOCK,TERMINAL,4 POLE 27 2 LNUT-05 Nut, Nylock, 10-24 UNC 28 4 PHPMS-22 8-32 UNC x 3/8 PHP MS SS 29 1 SHSS-36 1/4-20 UNC x 1/4 SH Set Screw SS SSxxx Base