PR POWER PR8000 Operation And Maintenance Manual
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PR POWER PR8000 Operation And Maintenance Manual

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  • Page 2: Table Of Contents

    PR8000 9mt 4x2000W METAL HALIDE INDEX CE MARK ..........................4 MAINTENANCE & OPERATION..................4 GENERAL INFORMATION ....................5 EQUIPMENT DOCUMENTATION FOR THE LIGHTING TOWER ........5 SAFETY SIGNS ........................6 SAFETY REGULATIONS TO OBSERVE ................8 BEFORE OPERATING THE MACHINE ................8 DURING MAINTENANCE ....................
  • Page 3 PR8000 9mt 4x2000W METAL HALIDE OPERATING INSTRUCTIONS ..................30 12.1 LIGHTING TOWER POSITIONING .................. 30 12.2 CONNECTING OF THE BATTERY .................. 30 12.3 CONNECTING OF THE STARTER MOTOR ..............30 12.4 EARTHING ........................30 12.5 PRELIMINARY CHECKS ....................30 12.6 ENGINE STARTING ......................

  • Page 4: Ce Mark

    The responsibility for the correct operation of the lighting tower depends on the operator. Before installation and operation of the lighting tower, read the manual carefully. If this manual is not clear or comprehensible, contact PR Power Australia wide on: 1300 399 499 All the specifications and pictures in this manual are subject to modifications without prior notice.

  • Page 5: General Information

    PR8000 9mt 4x2000W METAL HALIDE 3. GENERAL INFORMATION The lighting tower is designed, produced and tested to meet the European Standards and to reduce the electrical risks in compliance with the laws. The manufacturer declines responsibility from any unauthorised modification of the product.

  • Page 6: Safety Signs

    PR8000 9mt 4x2000W METAL HALIDE SAFETY SIGNS These signs inform the user of any danger which may cause injury. Read the precautions and descriptions below: Danger signs Description • Read the instruction handbook before operating the lighting tower. • Danger of electric discharges.
  • Page 7 PR8000 9mt 4x2000W METAL HALIDE • Danger possible spillage of corrosive substances • Danger possible crush point Prohibition signs Description • It is prohibited to clean, lubricate or regulate moving parts. • It is prohibited to extinguish fires with water, use fire extinguishers only.

  • Page 8: Safety Regulations To Observe

    The unit must be connected to the earth using a copper cable with a minimum cross-section of 6 mm². • PR POWER is not responsible for any damage caused by failure to earth. 5.2 DURING MAINTENANCE • Always turn off the lighting tower before any maintenance.

  • Page 9: General Danger Information

    PR8000 9mt 4x2000W METAL HALIDE GENERAL DANGER INFORMATION DANGER OF BURNS • Do not touch hot surfaces with hands e.g. silencers and engine when it is operating. • Do not touch the floodlights when turned on. • Always use gloves.

  • Page 10: General Description Of The Lighting Tower

    PR8000 9mt 4x2000W METAL HALIDE 7. GENERAL DESCRIPTION OF THE LIGHTING TOWER The PR8000 has been designed to take into consideration 3 fundamental characteristics: • Compact design • Reliability • Quality manufacturing and design The construction materials used, guarantee not only extreme strength of the tower, but they are also synonymous of longer life, in fact these materials are protected against oxidation like rust.

  • Page 11: Technical Specification

    PR8000 9mt 4x2000W METAL HALIDE 9. TECHNICAL SPECIFICATION 9.1 GENERATOR Model Synchronous Three phase voltage 20 kVA - 415 V Frequency 50 Hz Cos ϕ Insulation class Mechanical protection IP 23 9.2 ENGINE Make/Type Kubota D1703-E2BG Number of cylinders 1647 cm...

  • Page 12: Hydraulic Gear Box

    PR8000 9mt 4x2000W METAL HALIDE 9.3 HYDRAULIC GEAR BOX 9.3.1 ELECTRICAL MOTOR Feeding 400 V 50-60 Hz ± 10% Power 2 HP Poles Mechanical protection IP55 9.3.2 GEAR PUMP Displacement 3,2 cm 210 bar Maximum pressure Factory setting pressure 180 bar...

  • Page 13: Lighting Tower

    PR8000 9mt 4x2000W METAL HALIDE 9.4 LIGHTING TOWER Maximum height 9 mt Raising Hydraulic Section Rotation Section 360° Floodlights group tilt 41° Electrical coiled cable 11G2,5 mmq H07RN-F Electrical cable of floodlights 3300 kg Maximum cable load Maximum wind stability...

  • Page 14: Floodlight

    PR8000 9mt 4x2000W METAL HALIDE 9.6 FLOODLIGHT Lamp Metal halide Power 4x2000 W IP 65 Degree of protection Constructor material of the body Die-cast primary aluminium UNI 5076 alloy Constructor material of lampholder Ceramic K12s-7 base Lampholder Dimensions (L x H x D mm) 535 x 540 x 250 The floodlight is protected by tempered glass and silicone seals.

  • Page 15: Lamp

    PR8000 9mt 4x2000W METAL HALIDE 9.7 LAMP The metal halide lamps used in the floodlights of the lighting tower provide a brighter lighting system than traditional halogen lamps. The metal halide lamp is a high intensity discharge lamp. In the event the lights are accidentally switched off, you must wait for the lamps to cool (about 15 minutes) before re-igniting.

  • Page 16: Identification Of External Components

    PR8000 9mt 4x2000W METAL HALIDE 10. IDENTIFICATION OF EXTERNAL COMPONENTS 10.1 LIGHTING TOWER BREAKDOWN Items Description Control panel door Engine inspection door Lockable battery and starting key insulator switch Hydraulic Controls Telescopic mast Floodlights Floodlights rotation handles Emergency stop button...
  • Page 17 PR8000 9mt 4x2000W METAL HALIDE Items Description Mast rotation locking pin Lifting hook Gas exhaust outlet Radiator cap Air outlet grill Hydraulic stabilizers Door engine inspection Door for papers TL116-11-00-03 01-04-2011...
  • Page 18 The unit must be connected to earth using a copper cable with a minimum cross-section of 6 mm². PR POWER is not responsible for any damage caused as a result of failing to earth. Make sure that the emergency stop button (18) is armed. If not, turn the grip handle in clockwise direction.

  • Page 19: Battery And Starting Switch

    PR8000 9mt 4x2000W METAL HALIDE 10.2 BATTERY AND STARTING SWITCH Items Description Lockable battery isolator switch Lockable starting key isolator switch The machine is supplied with the battery switch disconnected (20). Connect the battery switch (20). If the lighting tower is not operating for long periods, we recommend you disconnect the battery switch (20).

  • Page 20: Radiator Cap Protection Plate

    PR8000 9mt 4x2000W METAL HALIDE 10.3 RADIATOR CAP PROTECTION PLATE Items Description Radiator cap protection plate To fill up and replace coolant, firstly lift the protection plate of the radiator cap and then unscrew the radiator cap. The coolant will last for one day if filled all the way up before operation start; therefore check the coolant level before every operation.

  • Page 21: Identification Of Inner Components

    PR8000 9mt 4x2000W METAL HALIDE 11. IDENTIFICATION OF INNER COMPONENTS 11.1 UPPER CONTROLS DESCRIPTION 32 31 30 Items Description Starting key Battery charge signal lamp Hour meter Preheater signal lamp Fuel gauge – Monitor fuel level Lever for floodlights group tilt...

  • Page 22: Lower Controls Description

    PR8000 9mt 4x2000W METAL HALIDE 11.2 LOWER CONTROLS DESCRIPTION Items Description 32 A main circuit breaker and 100 mA RCD for alternator 16 A main circuit breaker and 40 A/30 mA RCD for light 1 16 A main circuit breaker and 40 A/30 mA RCD for light 2...

  • Page 23: Controls Levers

    PR8000 9mt 4x2000W METAL HALIDE 11.3 CONTROLS LEVERS Items Description Raising and lowering lever (E) Raising and lowering lever for front left stabilizer (D) Raising and lowering lever for front right stabilizer (C) Raising and lowering lever for rear left stabilizer (B)

  • Page 24: Hydraulic Gear Box

    PR8000 9mt 4x2000W METAL HALIDE 11.4 HYDRAULIC GEAR BOX Items Description Engine hydraulic gear box Oil pressure gauge indicator Hydraulic oil tank cap Hydraulic oil tank Regularly check the level of hydraulic oil. Add oil if the level dips down lower than half a tank (total tank capacity 20L).

  • Page 25: Lowering Handle Bar Bracket In Case Of Emergency

    PR8000 9mt 4x2000W METAL HALIDE 11.4.1 LOWERING HANDLE BAR BRACKET IN CASE OF EMERGENCY Items Description Handle Manual pump WARNING: It is strictly prohibited to raise the stabilisers when the lighting tower mast is raised. In the event of damage to the hydraulic pump or generating set, it is possible to move the hydraulic components of the lighting tower by using the manual pump installed.

  • Page 26: Battery

    PR8000 9mt 4x2000W METAL HALIDE 11.5 BATTERY Items Description 80 Ah 12 V battery The lighting tower is supplied with the battery switch disconnected (20). Connect the battery switch (20). The battery fluid contains Sulphuric Acid which is extremely corrosive and harmful to the skin.

  • Page 27: Fuel Tank

    PR8000 9mt 4x2000W METAL HALIDE 11.6 FUEL TANK Items Description Fuel tank cap Fill up the tank with diesel fuel to the tank capacity (180L). The amount of fuel available can be determined by viewing the the fuel indicator (27) located on the control panel.

  • Page 28: Engine Oil Cap

    PR8000 9mt 4x2000W METAL HALIDE 11.7 ENGINE OIL CAP Items Description Engine oil cap Oil level indicator Check the engine oil level before starting the lighting tower or five minutes after stopping. Do not discharge polluting liquids into the atmosphere.

  • Page 29: Change Engine Oil

    PR8000 9mt 4x2000W METAL HALIDE 11.8 CHANGE ENGINE OIL Items Description Engine oil drain cap Manual pump for extracting the oil from the engine Wiggins Fast Fuel (*) Use the manual pump to change oil. Remove the discharge cap (57) from the pump and apply a rubber hose (not supplied) to the top.

  • Page 30: Operating Instructions

    PR8000 9mt 4x2000W METAL HALIDE 12. OPERATING INSTRUCTIONS 12.1 LIGHTING TOWER POSITIONING Place the lighting tower on a level surface, ensuring not to exceed 10° inclination. Choose an open and ventilated location, ensuring discharge of the exhaust fumes happens well away from the work-zone.

  • Page 31: Running In

    PR8000 9mt 4x2000W METAL HALIDE Note: If the engine fails to start, turn the key to the “OFF” position and wait 10 seconds before restarting. Let the engine run for about 5 minutes to warm up. 12.7 RUNNING IN For the first 50 hours of operation, do not employ more than 70% of the maximum power indicated in the technical specifications.

  • Page 32: Remarks

    Before operating lighting tower it is recommended the authorised staff read and understand all warnings and dangers described in this manual. PR POWER is not responsible of any damage to equipment or persons, as a consequence of not adhering to the safety guidelines.

  • Page 33: Use Of The Lighting Tower

    PR8000 9mt 4x2000W METAL HALIDE 12.11 USE OF THE LIGHTING TOWER Before operating the lighting tower it is recommended that the operator read and understand the manual. Rotate the floodlights in the position you require, unscrewing the stop nut on the floodlight support.
  • Page 34 PR8000 9mt 4x2000W METAL HALIDE Start the engine like described at the chapter “12.6 ENGINE STARTING”. Check that the circuit breaker (Fig. 5) on the control panel is in the “ON” position. (Fig. 5) Lower the front and rear stabilisers via the control levers located along side the control panel (Fig.
  • Page 35 PR8000 9mt 4x2000W METAL HALIDE Refer to the spirit level for the correct stability of the lighting tower (Fig. 8). Warning! It is not possible to raise the tower if all stabilisers are not correctly positioned. (Fig. 8) The Mast Control Lever located on the control panel allows the mast to be raised and lowered (Fig.
  • Page 36 PR8000 9mt 4x2000W METAL HALIDE Tilt the floodlights via the control lever (Fig. 11). Maximum tilt is approximately 41°. (Fig. 11) In the event the lights are accidently switched off, wait for the lamps to cool (about 15 minutes) before a re-lighting.

  • Page 37: Stopping The Engine

    PR8000 9mt 4x2000W METAL HALIDE WARNING: It is strictly prohibited to raise the stabilisers when the lighting tower is in vertical position at its maximum height. WARNING: The lighting tower is designed to withstand 110 km/h winds at its maximum height.

  • Page 38: Lighting Tower Maintenance

    It is the Manufactures recommendation that all cables and pulleys are replaced as required. If the steel cable shows unusual signs of wear or damage, do not use the lighting tower and contact PR Power. 13.6 CHECK OF HYDRAULIC CONNECTIONS Check the connections for the hoses that transport the hydraulic oil from the tank to the cylinder.

  • Page 39: Troubleshooting Guide

    PR8000 9mt 4x2000W METAL HALIDE 14. TROUBLESHOOTING GUIDE Listed below are the most common issues that may occur during operation of the lighting tower and possible remedies. If the engine does not operate correctly, we recommend you follow the maintenance operations and the maintenance schedules as described in the engine “Operator’s manual”...
  • Page 40 PR8000 9mt 4x2000W METAL HALIDE FAULT • The starter motor works, but the engine does not start. CAUSE Possible lack of fuel in the tank. REMEDY Refuel the machine. CAUSE Fuel filter is dirty. REMEDY Replace the fuel filter. CAUSE The fuel pump does not work.
  • Page 41 The engine is set to the correct speed. CAUSE The alternator is defective. REMEDY Replace the alternator and if problem continues contact PR POWER. FAULT • The lighting tower shuts down. The low oil pressure indicator light is on. CAUSE The oil level is low.
  • Page 42 CAUSE The battery is defective. REMEDY Replace the battery. CAUSE The engine’s alternator fails. REMEDY Check it alternator and if problem continues contact PR POWER. CAUSE The engine protection panel “DAS” TP0401 is defective. REMEDY Replace the panel. FAULT •...
  • Page 43 Check the electrical system connected to the auxiliary socket, check that the amp draw does not exceed the required level. CAUSE Electrical connections interrupted. REMEDY Check the external electrical system and if the problem continues contact PR POWER. CAUSE Connection to Earth not correctly carried out. REMEDY Check that the connection to Earth is correct.
  • Page 44 Check that the automatic earth leakage relay is armed. If it is not armed rearm it. Check the electrical system of the hydraulic gear box. Check the oil level inside the hydraulic gear box, and top up if necessary. Replace the hydraulic gear box and contact PR POWER directly. FAULT •...

  • Page 45: Replace The Lamp And Lenses

    PR8000 9mt 4x2000W METAL HALIDE REMEDY The lamp could not be relight, it is necessary to wait for the lamp to cool down(about 15 minutes). CAUSE The automatic earth leakage relay has been tripped. REMEDY Rearm the automatic earth leakage relay.

  • Page 46: Spare Parts

    PR8000 9mt 4x2000W METAL HALIDE 16. SPARE PARTS 16.1 UPPER COMMAND PANEL SPARE PARTS LIST Items Code Denomination Starting key (Kubota engine part) 6205 Battery charge signal lamp 6184 Female 2 ways faston holder 9328 12 V 50 Hz hour meter...

  • Page 47: Lower Command Panel Spare Parts List

    PR8000 9mt 4x2000W METAL HALIDE 16.2 LOWER COMMAND PANEL SPARE PARTS LIST Items Code Denomination 12732 100 MA 4P automatic earth leakage relay 12677 Lock din left hand locking assembly 12675 32 A 3P main circuit breaker 6239 40A/30mA RCD...

  • Page 48: Control Panel Door Spare Parts List

    PR8000 9mt 4x2000W METAL HALIDE 16.3 CONTROL PANEL DOOR SPARE PARTS LIST Items Code Denomination Lockable battery insulator switch 12568 Hydraulic gear box door 8766 Hinge 12489 Command panel door 12706 PG21 d.20,5 press metal sheath 12705 PG16 d.15,5 press metal sheath...

  • Page 49: Central Panel And Radiator Support Spare Parts List

    PR8000 9mt 4x2000W METAL HALIDE 16.4 CENTRAL PANEL AND RADIATOR SUPPORT SPARE PARTS LIST Items Code Denomination 12484 Central panel 12491 Collector air filter 12728 60-80 metal clamp 12665 Pre-cleaner 12663 Filter bracket 12664 FPG radial 90° filter 12226 Air filter support...

  • Page 50: Spare Parts List Hydraulic Parts

    PR8000 9mt 4x2000W METAL HALIDE 16.5 SPARE PARTS LIST HYDRAULIC PARTS Items Code Denomination 12628 Hydraulic gear box complete 12458 Hydraulic cylinder oil tube 12459 Left front stabilizer oil hose 12460 Right front stabilizer oil hose 12461 Left rear stabilizer oil hose...

  • Page 51: Spare Parts List For Solenoid And Engine Support

    PR8000 9mt 4x2000W METAL HALIDE 16.6 SPARE PARTS LIST FOR SOLENOID AND ENGINE SUPPORT Items Code Denomination 6843 50x50x100 solenoid 6882 M6 rope tightener 11714 Bowden sheat 11686 Tightener plate 11710 Wire pin 6878 Bobden pawl 6881 Bowden wire 11614...

  • Page 52: Spare Parts List For Frame

    PR8000 9mt 4x2000W METAL HALIDE 16.7 SPARE PARTS LIST FOR FRAME TL116-11-00-03 01-04-2011...
  • Page 53 PR8000 9mt 4x2000W METAL HALIDE Items Code Denomination 12191 Rudder spacer 10695 2000 W ballast with capacitor 11275-3 Ballast cover 10695-1 60µF capacitor with ballast 12725 Electrical box 11619 Ballast support 7-28-29 12428 Hydraulic stabilizer front right 7668 12 V 80 Ah battery...

  • Page 54: Spare Parts List For Canopy

    PR8000 9mt 4x2000W METAL HALIDE 16.8 SPARE PARTS LIST FOR CANOPY TL116-11-00-03 01-04-2011...
  • Page 55 PR8000 9mt 4x2000W METAL HALIDE Items Code Denomination 12479 Mast guide flange 9858 Mast guide flange 9859 Front flange 8178 Lock pin 12306 Mast position plate 12307 Mast position plate 9901-1-Z Mast guide flange 12480-Z Mast guide flange with blocking...

  • Page 56: Spare Parts List For Telescopic Mast

    PR8000 9mt 4x2000W METAL HALIDE 16.9 SPARE PARTS LIST FOR TELESCOPIC MAST TL116-11-00-03 01-04-2011...
  • Page 57 PR8000 9mt 4x2000W METAL HALIDE Items Code Denomination 11277-12 Thrust assembly 6231 Hydraulic cylinder lower pin 12458 Hydraulic cylinder tube 9560 Hydraulic cylinder 12207 1° section mast 9542 2° section mast 6230 Hydraulic cylinder top pin 9543 3° section mast 12993 High Rated 3.3 tonne Steel cable (l 1400 Ø...

  • Page 58: Lamps Spare Parts List

    PR8000 9mt 4x2000W METAL HALIDE 16.10 LAMPS SPARE PARTS LIST TL116-11-00-03 01-04-2011...
  • Page 59 PR8000 9mt 4x2000W METAL HALIDE Items Code Denomination 9477 Floodlights support 9476 Floodlights support 11991 6205 2RS bearing 9479 Ropes protection 1061 Ø 16 ½” gas press sheath 7531 15/15 clamp 12703 PG13,5 d.10 press metal sheath 12254 3 A 240 V AC security sensor...

  • Page 60: Spare Parts List For Alternator

    PR8000 9mt 4x2000W METAL HALIDE 16.11 SPARE PARTS LIST FOR ALTERNATOR TL116-11-00-03 01-04-2011...
  • Page 61 PR8000 9mt 4x2000W METAL HALIDE Items Code Denomination 12116 PRO18SA/4 Linz alternator complete Frame with stator B14 rotation inductor SAE rotating inductor E18SE001A Rear shield E18SB013 B3/B14 front cover SAE front cover Terminal box E18BT004B Terminal box cover E18KA002D Rear cover...

  • Page 62: Trailer For Fast Towing Height Adjustable Spare Parts List

    PR8000 9mt 4x2000W METAL HALIDE 16.12 TRAILER FOR FAST TOWING HEIGHT ADJUSTABLE SPARE PARTS LIST Items Code Denomination 12440 Trailer for fast towing height adjustable 7723 M10 female eyebolt 12696 12697-680 Chain (*) Please specify clearly the parts required TL116-11-00-03...

  • Page 63: Spare Parts List For Stickers For Lighting Tower

    PR8000 9mt 4x2000W METAL HALIDE 16.13 SPARE PARTS LIST FOR STICKERS FOR LIGHTING TOWER Sticker Code 10178 10182 10179 10181 10180 10185 10183 10184 12546 DANGER HIGH VOLTAGE EARTH 12559 STAKE EMERGENCY 12545 STOP BATTERY 12547 ISOLATOR 12668 MEN LINK...
  • Page 64 110 Km/h PR8000 OPERATION INSTRUCTIONS PRE-START CHECK Read the PR8000 Operating Manual, before operating the equipment. Ensure the lighting tower is positioned on level ground. Check the spirit levels (located on top of the canopy) for correct levels. Ensure ALL four stabiliser legs are fully deployed and in position.
  • Page 65 PR8000 9mt 4x2000W METAL HALIDE PR Power 36 Attwell St, Landsdale, WA, Australia +61 89303 3000 - www.prpower.com Year of manufacture: 2011 Type PR8000 Engine Kubota Alternator PRO18SA/4 12347 415 Y 1500 I.CL. Dimensions L x W x H 3630 x 1690 x 2580 mm...

  • Page 66: Wiring Diagram

    PR8000 9mt 4x2000W METAL HALIDE 17. WIRING DIAGRAM TL116-11-00-03 01-04-2011...
  • Page 67 PR8000 9mt 4x2000W METAL HALIDE 36 Attwell St, Landsdale, WA Australia Tel. +61 89303 3000 e-mail: www.prpower.com TL116-11-00-03 01-04-2011...

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