Mea SMAC 35DG Owner's manual

7209-D0001
SMAC 35DG / DWG
22HP
Owner’s / Operator’s Manual
35 CFM Diesel Driven Air Compressor and
Generator / Welder Generator
Revision: 3
Reviewed: 22-03-2023

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THIS PAGE IS LEFT
BLANK
INTENTIONALLY.

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MEA Product Registration Form
THE ATTACHED FORM MUST BE COMPLETED
AND
RETURNED WITHIN 30 DAYS OF INSTALLATION
OR
WARRANTY WILL BE VOID
ALTERNATIVELY, PLEASE GO ONLINE AND
COMPLETE WARRANTY FORM
www.mobileenergyaustralia.com.au/warranty-registration

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MEA Product Warranty Registration Form
This form must be completed and returned to MEA at the time of
Installation. This will assist MEA in processing the product in the
unlikely event that a warranty claim is needed
MEA Dealer Information
Company Name: _____________________________________________________________
City: _______________ State: ___________________ Country: ___________________
MEA Installer Information
Company Name: ______________________________________________________________
City: _______________ State: ___________________ Country: ___________________
Installation Date: _______ / ________ / ______
Day Month Year
Owner Information
Company Name: ______________________________________________________________
Address: _____________________________________________________________________
City: _______________ State: ___________________ Country: ___________________
Postcode: _________________________ Phone #: ________________________________
Product Information
MEA Serial Number: __________________________________________________________
Model Number: _______________________________________________________________
CUT HERE

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TABLE OF CONTENTS
1. COMPRESSOR / COMPRESSED AIR SAFETY..............................................................6
2. SPECIFICATIONS............................................................................................................9
3. OPERATING PROCEDURES.........................................................................................11
5. SCHEDULE MAINTENANCE.........................................................................................19
6. SPARE PARTS AND SERVICE KITS............................................................................21
7. TROUBLESHOOTING....................................................................................................22
8. DRAWINGS & ILLUSTRATIONS...................................................................................24
9. WARRANTY ...................................................................................................................33
10. MOBILE ENERGY AUSTRALIA - CONTACTS............................................................35
11. APPENDIX A –DESIGN REGISTRATION...................................................................36
PLEASE USE QR CODE TO LINK YOU TO RELEVANT MSDS ......................................37
Both the MEA Product Warranty Registration form and the Kubota Warranty Registration
form must be completed and returned to MEA.

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1. COMPRESSOR / COMPRESSED AIR SAFETY
(COMPRESSOR / COMPRESSED AIR)
MEA DISCLAIMS ALL LIABILITIES FOR DAMAGE OR LOSS OF EQUIPMENT AND PROPERTY,
PERSONAL INJURIES (INCLUDING DEATH), AND CONSEQUENTIAL DAMAGES ARISING OUT OF
ANY MEA SYSTEM NOT USED IN ACCORDANCE WITH THE OPERATOR’S MANUAL.
ALL UNITS ARE SHIPPED WITH A DETAILED OPERATOR’S MANUAL. THIS MANUAL CONTAINS
VITAL INFORMATION FOR THE SAFE USE AND EFFICIENT OPERATION OF THE UNIT. READ THE
OPERATOR’S MANUAL BEFORE STARTING THE UNIT. FAILURE TO ADHERE TO THE
INSTRUCTIONS COULD RESULT IN SERIOUS BODILY INJURY OR PROPERTY DAMAGE.
Care is required when working with an air compressor or compressed air. Compressed air is one of the many
way’s energy can be stored. Releasing the stored energy in an uncontrolled manner can result in catastrophic
consequences. Death and permanent disability are possibilities that can occur. The following are suggested
as minimum requirements to be followed when operating the MEA SMAC system. It is important that each
work site shall perform a risk analysis and produce a procedure to eliminate or control the hazardous
condition to minimise the risk to personnel and equipment. Health and Safety Regulations necessitate that
this is a compulsory process to be carried out on each site. These, together with site specific safety
procedures will help to minimize the risk to accidents, personnel injury, and loss of life. It is the responsibility
of the employer to ensure that the work site is safe for all employees and that the safety procedures are
followed by all employees.
SAFETY WHEN OPERATING AN AIR COMPRESSOR
•Do not bypass or disable the oil temperature and pressure sensors –unless planning on running to
failure (MEA does not recommend the practice).
•Do not expose the tank or compressor to extreme heat.
•Do not perform any service or repairs until the system has been completely relieved of air pressure.
•Maintenance and repairs on the system should only be done by qualified personnel.
•Do not operate the compressor while driving.
•Do not tamper with the pressure relief valve.
•Follow safe work practice, wear the appropriate personal protective equipment (PPE) when operating
air-powered equipment, particularly eye and hearing protection.
•Avoid contact with rotating components, ensure all safety guards are in place.
•Avoid all contact with pressurized air. If it penetrates the skin, it can enter blood stream and cause
death.
•Vaporized oil propelled by high pressure is an explosive mixture. To prevent compressor explosion
or fire, make sure that the air entering the compressor is free of flammable vapours.
•Do not breathe the compressor air, vaporized oil is a respiratory hazard.
•Stay clear of all moving parts when the system is operating.
•Follow safety procedures for tyre service operations as set by the authority.

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2. SPECIFICATIONS
Compressor Type: Oil injected rotary screw compressor
Drive System: Diesel powered via direct mechanical coupling
Control: Pneumatic
Maximum Air Delivery 35 CFM @ 150 psi
Pressure Regulation: Mechanical inlet control valve modulates flow in response to demand
Inlet Valve Regulation Pneumatic
Engine Control System: Pneumatic speed control, engine and compressor high temperature and
pressure engine shutdown system
Safety Features 200 PSI relief valve in compressor sump
Temperature safety sensor in the compressor
Rapid blow-down valve to discharge system pressure on shutdown
Lubrication: All replacement compressor oils must be approved by MEA prior to use.
Warranty will be nullified if oil has not been approved.
MEA certified and approved semi synthetic compressor oil
Part Number 10019 –P0002
Quantity of Compressor Oil Required –4 Litres
Filters Paper-type replaceable air filters
Spin-on type compressor oil filter
Spin-on type Coalescing filter element
Generator Option: Single or 3 Phase Generator Features
•2 Poles
•Single Phase AC 5 to 8.5 kVA
•3 Phase AC 7.5 to 10 kVA
•IP23
Generator Welder Features
•2 poles brushless alternating-current rotating welders
•Protection: IP 23
•Weldable electrodes: rutile
•Supplied with auto resettable thermal breaker against overload
•Can also be used as single-phase alternator

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Engine Model: Kubota D902
Engine Type: 3 Cylinder, water cooled, Diesel Combustion Engine
Power (continuous): 18 Kw (22 HP) @ 3600RPM
Electrical System: 12 Volts DC
Maximum RPM: 3150 max rpm in compressor and generator mode
Direction of Rotation: counter clockwise (viewed from flywheel)
Engine Control System: Electric push button start pneumatic speed control via air cylinder.
Engine Protection: Engine low oil pressure and high-coolant temperature sensors.
Lubrication: MEA approved oil to meet strict emission control regulations, min. class “CF”
or better is required. If oil does not meet the minimum requirements, all
warranty will be nullified.
IMPORTANT:
Engine oil should be MIL-L-2104F or have properties of API classification CF
grades or higher. Change the type of engine oil according to the ambient
temperature.
Above 25°C (77°F) SAE30 or SAE10W-30 or SAE15W-40.
0°C to 25°C (32°F to 77°F) SAE20 or SAE10W-30 or SAE15W-40
Below 0°C (32°F) SAE10 or SAE10W-30 or SAE15W-40
Engine Oil quantity 2.5L
Filters: Air Filter - Paper-type replaceable (Not Possible to Clean)
Spin-on type fuel filter (Not Possible to Clean)
Spin-on type oil filter - Spin on type (Not Possible to Clean)
Engine fuel filter –In Line Element (Not Possible to Clean)

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3. OPERATING PROCEDURES
PRE-START CHECK EACH DAY
1. Check the oil level in the engine.
2. Check the water level in the engine.
3. Check the oil level in the compressor
4. Check all hoses are secured and not damaged. Replace all damaged hoses before starting.
5. Check all electrical cables are secure. Secure all cables that are not tied down.
6. Check the air inlet and air filter on the engine are clear.

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STARTING / STOPPING DIESEL ENGINE AND COMPRESSOR –NEW CONTROL BOX
Note: Wiring harness has blue trace for ID. Not interchangeable to previous version i.e.,
key ignition starts.
STARTING THE DIESEL ENGINE
1. Check the COMPRESSOR ROCKER SWITCH is set to the OFF position (centre position).
2. Press the ON/OFF/GLOW rocker switch to the LOWER POSTION –this is the Glow hold and it will
disengage if you release. Do not hold this position for longer than 15 seconds. The system could be
damaged should you extend the time beyond the 15 seconds. Releasing glow hold will leave the system
in OFF position (middle position).
3. Ensure ON/OFF/GLOW Switch still in ON position (Upper position). Start the engine by depressing the
START SWITCH –The engine should turn on immediately. Hold the switch for no longer than 10
seconds.
4. If the engine does not start, check the fuel tap if there is one and repeat the process described in 2 and
3 above. The maximum number of attempts should be limited to 4 and after this; the operator should
seek assistance from a mechanic.
5. Allow the engine to run at no load for 2-3 minutes. This will allow the engine to warm up and lubrication
system to be fully operational before the load is applied.

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STARTING THE COMPRESSOR
1. Set the COMPRESSOR SWITCH to the ON position. This will engage the compressor load solenoid.
The engine speed will increase until the pre-set regulated pressure is reached.
2. Listen for air escaping from the pressurized air system. Ensure all airline taps are closed so that
compressor outlet air can reach regulated pressure.
3. If the escaping air is from a broken pipe or connection, turn the COMPRESSOR SWITCH to the OFF
position. Stop the diesel engine. Advise the maintenance department for their assistance.
4. The engine will reduce its RPM when the compressor reaches the pre-set regulated pressure. (It should
be noted the pre-set regulated pressure can be adjusted via the regulator control valve. It is
recommended that your maintenance department does this if required.)
5. The compressor is ready to use.
STOPPING THE COMPRESSOR UNIT
1. Disengage the compressor by moving the compressor engage switch to the “Compressor Off” position.
2. The compressor will shut down and bleed off pressure. The engine will come down to idle speed.
3. It is good practice to allow the engine to run under no load for 2-3 minutes.
4. Turn the engine off by pressing the ON/OFF/GLOW rocker switch to the centre position. If you hear a
slight “hissing” noise this is normal, the compressor is bleeding off excess pressure out of the system.
OPERATING THE GENERATOR
1. Start engine as per previous instruction.
2. Plug the electrical load into the outlets and switch outlets on.
3. As soon as the device is switched on, the automatic current sensing device will unload the compressor
and either increase or decrease the RPM of the engine to maintain a constant 3100rpm thus maintaining
the load until the load is switched off.
4. When the load is switched off the engine will idle down in under 10 seconds.
5. When operating the welder, press down the HYDRAULICS (OPTION) side of the switch, this will
manually rev up the engine in order to weld. When finished welding, press down the COMPRESSOR
ON side of the switch to bring the switch back to the central position this will make the engine rev down.
Note:
When operating the SMAC unit, only one device can operate at one time, either the compressor or the
generator/welder generator. When operating the compressor, the diesel engine will increase speed until it
reaches 3100rpm to deliver 35cfm. When using the generator, the compressor will be unloaded through the
unloading valve. The diesel engine will maintain a constant 3100rpm to ensure consistent power regulation to
the generator.

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4. INSTALLATION
ENSURE THAT A WATER SEPARATOR IS MOUNTED AS FAR FROM THE COMPRESSOR AS POSSIBLE
OR THAT IT HAS AT LEAST TWO METRES OF HOSING BETWEEN THE COMPRESSOR DISCHARGE
AND SEPERATOR INLET.
The compressor air intake is protected by a paper-type replaceable air filter, and a spin-on type oil filter for the
oil side and a coalescing filter for final oil removal from the air.
Safety features included in the compressor are:
▪200 PSI relief valve in separation manifold.
▪Blow-down valve to discharge system pressure on shutdown - will not allow compressor restart until
system pressure bellow 5PSI.
▪Over temperature safety sensor in the compressor oil.
▪Over pressure control mounted at the minimum pressure valve.
▪Do not disable or bypass the over-temperature shutdown circuits. Failure of the shutdown
system could result in equipment damage, injury, or death.
The information in this section is very important for proper operation of the compressor. Read these
requirements before beginning installation. The following is a view of the compressor/diesel engine unit.

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1. General Consideration Mounting the Compressor Unit
The starting point for the installation is a quick overview of the requirements. Some of these points will
be dealt with in more detail further on in this text. Things that should be considered now are as follows.
1. The unit should be installed in a well-ventilated area.
2. The unit will need to be installed level and any variation in the frame to be supported via washers
for spacers and properly secured to the vehicle with no less than 4 high tensile fasteners 8.8
grade or higher.
3. In installation, the unit should be orientated that the sight level glass for oil level can be checked
easily.
4. It should also allow for ease of servicing without having to disconnect lines or remove and
reposition the unit.
5. The unit should be protected from excessive exposure to the elements and possible incidental
damage from other operations.
6. The unit should be installed in an area away from heat sources such as engines, exhaust
systems or other components that generate heat.
7. The unit should not be installed in a location where it will be exposed to high contamination
levels or combustible gases.
8. The engine exhaust should be routed away from the compressor unit. The engine exhaust
should be in an area where the exhaust CANNOT be filled up with rain (an exhaust flapper is
fitted to the exhaust) however the exhaust must not face directly down to the ground.
2. Mounting of Compressor Unit considering Ventilation
It is not possible to make absolute recommendations regarding ventilation because of the widely
differing circumstances that are possible. Duty cycle, ambient temperature and enclosure shape are
some of the important variables. Ideal ventilation will provide good airflow through the unit with no
restrictions. There are two ways in which the SMAC compressor can be mounted.
1. Top or Deck Mounting
This is the preferred mounting location. Placing the unit in an area where there are no restrictions on
the intake of fresh air and exhausting of hot air and exhaust gases. This provides the best cooling and
ensures reliability and life for the compressor / diesel engine driven unit.
2. Enclosed Mounting
It is important that the persons installing the unit and the manufacturer discuss if it is going to be placed
in an enclosed area.
Ventilation is one of the most important things to consider when looking at installing a diesel engine
driven compressor in an enclosed area.
It is important that the air intake to the compressor and the engine exhaust are located outside of the
enclosed space. The unit generates a considerable amount of heat when running. Proper ventilation
is vital for ideal operation and to avoid damage to components.
Ensure there is a minimum of 10" (250 mm) clearance between cooler grills on SMAC and any other
components mounted on the vehicle. It is strongly recommended that the installation is tested in the
event that the unit is installed in an area considered to be enclosed mounting.

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The following is a method suggested for testing.
2.1 It is best to test the installation at the hottest expected ambient temperature.
2.2 Setup and run the system at 120 PSI. This can be done by installing a ball valve on the air
outlet pipe and adjusting the opening of the valve so that the compressor is running
continuously at 120 PSI.
2.3 Record the engine, compressor, and current ambient temperature for future reference.
2.4 Run the system at full load for at least one hour or until the temperatures stabilizes.
Temperature stabilizing means there is no rise in temperature for 15 minutes when the
compressor is running at the rated load.
2.5 Record the engine and compressor temperatures every 10 minutes.
2.6 If the system over-heats, the ventilation is not sufficient, review the installation, make changes
as needed, and repeat the test.
3. Engine Exhaust consideration when installing Diesel Engine Driven Compressor
In cases that the exhaust system needs to be ducted away from the engine assembly, the following are
a minimum that should be considered
▪The exhaust pipe needs to be adequate for the engine.
▪There needs to be a flexible joint at the point where the extension is connected to the exhaust
system of the Diesel Engine Driven Compressor Unit.
▪Ensure the exhaust pipe has suitable clearance and does not contact anything.
▪Ensure that if the exhaust outlet has a method to prevent water from entering the engine
▪Ensure exhaust from the diesel engine is routed in a way to prevent recirculation back into the
unit.
4. Securing the Diesel Engine Driven Compressor Unit to the body of the vehicle.
It is important to consider maintenance needs, (daily needs), service requirements, electrical
connections, air connections, location of control panel before the SMAC is secured to the body of the
vehicle.
▪Locate a suitable mounting position for SMAC. Place the unit and check for clearances to any
other objects.
▪There are four weld nuts located at the four corners of the bottom formed plate which can be
used as mounting bolt locations. Holes can also be drilled through the bottom of the formed
plate if alternate locations are required.
▪Drill four holes in mounting surface and secure the SMAC to the truck. Use a minimum of 4 –
M12 high tensile bolts, 8.8 grade minimum.

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5. Connecting Truck Electrics to the Diesel Engine Driven Compressor Unit
Electrical connection of SMAC to the truck is very simple. The entire control system is mounted in the
SMAC.
1. The SMAC needs to be connected to the truck battery. A minimum of 25mm cable is required
for the connection because the SMAC is started using the truck battery. SMACD units are 12
Volt DC. If a truck is 24 Volt DC (Two of 12 Volt DC batteries are supplied in the truck),
connection for the SMAC Unit will be across 1 of the batteries.
2. Start switch control box which includes the compressor load and unload switch needs to be
connected to the SMAC front panel via the Deutsch plug provided at the end of the 5-metre
cable of the control box. It should be noted; this switch box can be mounted in the cab of the
vehicle if an extension harness is purchased or any location on the truck body.
6. Connection of the Diesel Engine Driven Compressor Unit to the fuel tank.
It is normal to use the trucks fuel tank for all models of the SMACD. The SMACD has as standard a fuel
pump built into it. It is suggested that an additional electrical fuel pump is installed if the compressor
unit is installed 20” (500 mm) above the height of the truck diesel tank. The following is the method for
connecting the fuel to the compressor unit.
1. Cut the feed and return lines at the tank. Install the tees into the cut pipes.
2. Install the provided check valve at the T-Piece of the feed pipe.
3. Connect the diesel feed pipe to the compressor unit from the check valve. Connect the return
line from the compressor unit to the return line tee.
PLEASE NOTE: IF THE SMAC IS ORDERED AS A BATTERY FUEL MODULE, THEN NO CONNECTION
TO THE VEHICLE IS REQUIRED
7. Remote Air Intake Filter Removed for Shipping (Optional).
A label on the unit will indicate if the Air Compressor Filter has been removed for the purpose of
shipping.
IT IS IMPORTANT THAT THE FILTER IS FITTED BEFORE THE COMPRESSOR IS STARTED.
The following is the instruction for fitting the filter to the compressor.
1. Remove the front access panel by pulling out the top of the panel until it is free of the rubber
mounts, lift to free from bottom rubber mounts.
2. Put the hose clamp over the air hose protruding through the top panel and push the Air Intake
Filter inlet tube into the hose.
3. Using the 2 off M8 x 30 bolts, flat washers, spring washers and nuts, bolt the Air Intake Filter
into place.
4. Tighten the hose clamp and refit the front panel.

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8. Completing the Installation - Before Checking the System
Make sure that the following have been completed before operating the MEA Diesel Engine Driven
Compressor Unit
1. Check the compressor oil level; make sure the compressor has been filled to the correct level
prior to shipping. Note that the oil is very clear, and it is difficult to see the level.
2. Check the engine coolant level.
3. Check the engine oil level.
4. Check fuel level.
5. Do a final inspection to make sure that all fasteners and connections are tight.
6. Check that all hoses and wiring are secure and protected.
9. Check Operation –Setup & Performance Testing of Diesel Driven Compressor.
1. The compressor is dispatched from the factory with the pressure pre-set to the customer
specification. Should the customer want to alter this setting, the instruction on how to do this
can be found in the compressor manual.
2. Install the ball valve on the outlet of the hose from the compressor. Set the ball valve to the
closed position.
3. On starting and running, the air pressure will be found to be at the pressure specified by the
customer and the engine will be at the lower speed (idle speed). The Unit has been adjusted
by the factory to the customer specification.
If the pressure is not at the specified pressure, refer to MEA before attempting any adjustments.
4. Use a spray bottle with soapy water to check for leaks in the air line. You will see soap bubbles
around any area with an air leak. Rectify any leaks you may find.
5. Keep the system running at the pre-set pressure until the compressor is up to operating
temperature.
6. Using the ball valve located on the outlet of the compressor, slowly open the ball valve, and
watch the pressure drop. The pressure will drop up to the point that the pressure is 20 PSI
below the setting detailed in 1 above. The engine will speed up to the maximum pre-set RPM.
7. Keep the opening of the ball valve at the setting described above for about 5 minutes. The
engine should continue to run at the maximum pre-set RPM.
8. Slowly close the ball valve and watch the pressure while closing. The engine will drop to the
lower speed when the regulated pressure is reached.
9. Your compressor is working correctly if it is operating as per this description.

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5. SCHEDULE MAINTENANCE
The maintenance intervals recommended are based on standard operating conditions. The intervals for
inspection, lubrication and maintenance given herein are maximum intervals and it should be noted to schedule
the maintenance accordingly to sites.
When the unit is being operated in a dusty environment, in high ambient temperatures or in other unusual
conditions, an assessment needs to be done for shorter service interval?
A planned program of periodic inspection and maintenance will help to avoid premature failure and costly
repairs. Daily visual inspections should become routine.
IMPORTANT: PLEASE CONTACT MOBILE ENERGY AUSTRALIA FOR MORE INFORMATION IF YOU
HAVE ANY QUESTIONS REGARDING THE SETUP AND OPERATION OF THE SMAC RANGE OF
PRODUCTS.

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Interval
Compressor
Diesel Engine
Action to be taken
Periodically During
Operation
Observe all gauge readings. Note any change from the normal reading and determine the
cause. Have the necessary repairs made? (Note: “Normal” is the usual gauge reading when
operating at similar conditions on a day-to-day basis.)
Every 10 Hours or
Daily
Check the compressor oil level.
Check engine oil level
Check air filter/s and connecting hose and clamps
Check for oil and air system, including hoses, for leaks
Check water level
Weekly Check
Check Cone locks on Exhaust Manifold are tight*
Every 25 Hours or
Monthly
Drain water from Compressor and check
oil level
After first 50 hours
of operation (7201-
K0017)
Change engine oil filter cartridge
Check system for oil and/or air leaks
Check all fuel hoses and clamping bands
Check engine/compressor/generator mounts for excessive wear and fastener torque.
Check shaft couplings for movements on shafts
Every 100 Hours
Check engine/compressor/generator mounts for excessive wear and fastener torque.
Check shaft couplings for movements on shafts. Check grub screws and bolts for tightness. If
fasteners have loose removed them, apply thread locking compound and retighten to required
torque.
Check compressor oil level
Change engine oil (see system specifications,
diesel engine, lubrication)
Check system for oil and/or air leaks
Clean air cleaner element
Check fan belt tension
Every 200 Hours of
Operation or 6
months
Check radiator hoses and clamping bands
Change engine oil filter cartridge
Change engine oil (see system specifications,
diesel engine, lubrication)
Change engine air intake filter if necessary
Every 400 Hours of
operation or 9
months Engine
compressor see
Service Kit List
Change compressor oil 3L
Change Engine oil
Change compressor oil filter
Change engine oil filter
Change compressor air filter
Replace in-line fuel filter element
Check engine fan belt
Check drive coupling
Check fuel filter if necessary
Check engine mounts
800 Hours / 18
months
Change compressor oil filter
Replace engine air filter and service as per 400 hrs
service
Change compressor coalescing filter
Change compressor air filter
Periodically or as
required
Inspect and replace spin-on coalescing
element if necessary
Inspect and clean oil cooler fins