Mea SMARTPACK 180-H Owner's manual

SMARTPACK 180-H
Owner’s / Operator’s Manual
FRAMED HYDRAULIC COMPRESSOR
Revision: 2
Date: 16/01/2023

Mobile Energy Australia Pty Ltd 39 Dulacca Street, Acacia Ridge QLD 4110 Australia ABN 98 674 578 946
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Mobile Energy Australia Pty Ltd 39 Dulacca Street, Acacia Ridge QLD 4110 Australia ABN 98 674 578 946
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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

Mobile Energy Australia Pty Ltd 39 Dulacca Street, Acacia Ridge QLD 4110 Australia ABN 98 674 578 946
P: [phone] E: [e-mail] www.mobileenergyaustralia.com.au
MEA Product Warranty Registration Form
This form must be completed and returned to MEA at the time of
Installation. Warranty will be void if this form is not received by MEA
within 30 days of installation.
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......................................................2
2. SPECIFICATIONS....................................................................................................6
3. OPERATING PROCEDURE.....................................................................................7
4. INSTALLATION........................................................................................................8
5. SERVICE INTERVALS .............................................................................................9
6. SPARE PARTS.......................................................................................................10
7. TROUBLE SHOOTING...........................................................................................12
8. DRAWINGS & ILLUSTRATIONS...........................................................................13
9. WARRANTY ...........................................................................................................22
10. MOBILE ENERGY AUSTRALIA - CONTACTS....................................................24
11. APPENDIX A –PRODUCT DESIGN REGISTRATION........................................25
12. APPENDIX B –FLUIDS & MATERIAL SAFETY DATA SHEETS.......................26
MEA Product Warranty Registration form and partner Product Warranty Registrations
must be completed and returned to MEA.

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1. COMPRESSOR / COMPRESSED AIR SAFETY
MEA DISCLAIMS ANY AND ALL LIABILITIES FOR DAMAGE OR LOSS DUE TO PERSONAL INJURIES,
INCLUDING DEATH, AND/OR PROPERTY DAMAGE INCLUDING CONSEQUENTIAL DAMAGES
ARISING OUT OF ANY MEA SYSTEM NOT USED IN ACCORDANCE WITH THE OPERATOR
INSTRUCTIONS.
ALL UNITS ARE SHIPPED WITH A DETAILED OPERATOR MANUAL. THIS MANUAL CONTAINS VITAL
INFORMATION FOR THE SAFE USE AND EFFICIENT OPERATION OF THIS UNIT. CAREFULLY READ
THE OPERATORS 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
ways energy can be stored. Releasing the stored energy in an uncontrolled manner can result in catastrophic
consequences. Death and permanent disability are all possibilities that can occur. The following are
suggested as minimum precautions to be used when operating the SMARTPACK Air Compressor. It is
important that each work site engages in a risk analysis of that site and produces procedures in order to
minimise injury to their employees. Health and Safety Regulations today require that this is a compulsory
process to be carried out on each site. These, with site specific designed safety precautions will help to
reduce accidents, personal injury, and loss of life. It is the responsibility of the employer to ensure that the
work site is safe for the employees.
SAFETY WHEN OPERATING AN AIR COMPRESSOR
•Do not bypass or disable the oil temperature sensor.
•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.
•Run the system at idle speed and under no load conditions for 2 to 3 minutes before turning the
system off to allow system cooling and lubrication to occur.
•Follow safe work practices, wear the appropriate safety equipment 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, your skin, it can enter your blood stream and
cause death.
•To prevent compressor explosion or fire, make sure that the air entering the compressor is free of
flammable vapors.
•Vaporized oil propelled by high pressure is an explosive mixture.
•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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HYDRAULIC SAFETY
ALL HYDRAULIC EQUIPMENT MUST BE TREATED WITH EXTREME
RESPECT AND CARE. AS THE WORKING FLUID IS UNDER EXTREME
PRESSURE, UP TO 5000PSI, WITH HIGH FLOW RATES GENERATING
HIGH HEAT, ALL APPROPRIATE SAFETY PRECAUTIONS MUST BE
TAKEN IN TO ACCOUNT AND SAFETY EQUIPMENT MUST BE WORN IF
IN CONTACT WITH THE EQUIPMENT UNDER OPERATION. ALL LEAKS,
NO MATTER HOW MINOR, MUST BE RECTIFIED IMMEDIATELY AND
ANY WEAR IN THE HOSES MUST BE ADDRESSED AND EQUIPMENT
REPLACED. HYDRAULIC INJECTION IS DANGEROUS AND LIFE
THREATENING AND EVEN A PINHOLE LEAK WILL BLANKET AN ENTIRE
ENCLOSED SPACE VERY QUICKLY WITH HAZARDOUS VAPORISED
HYDRAULIC OIL MIST.

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P: [phone] E: [e-mail] www.mobileenergyaustralia.com.au

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Mobile Energy Australia Pty Ltd 39 Dulacca Street, Acacia Ridge QLD 4110 Australia ABN 98 674 578 946
P: [phone] E: [e-mail] www.mobileenergyaustralia.com.au

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P: [phone] E: [e-mail] www.mobileenergyaustralia.com.au
2. SPECIFICATIONS
Compressor Model: SMARTPACK 180H
Compressor Type: Oil flooded rotary screw compressor
Hydraulic Motor Type: 62cc Gear Motor
Control: 24V/12V Electronic Control
Maximum Air Delivery: 180cfm @ 150psi
Oil Flow Requirements: 138 LPM
Oil Pressure (Nominal): 200 Bar
Drive coupling speed: 2230 rpm
Pressure Regulation: Mechanical Inlet control valve modulates flow in response to demand
Safety Features: 200 PSI relief valve in compressor sump
Temperature safety sensor in compressor
Rapid blow-down valve to discharge system pressure on shutdown
Lubrication: MEA Certified and Approved Oil

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3. OPERATING PROCEDURE
CAREFULLY READ THE OPERATING INSTRUCTIONS BELOW. FAILURE TO
ADHERE TO THE FOLLOWING COMPRESSOR OPERATING INSTRUCTION
COULD RESULT IN SERIOUS INJURY.
1. Check Oil Level
2. Check Hoses and fittings for leaks. Make sure the hoses are not loosened nor damaged.
3. Check and make sure hydraulic supply/return (drain if applicable) are installed correctly.
4. Check Air Filter for Blockage.
5. Check the Safety circuit switch operation (Reset Switch).
6. Switch on the vehicle and activate the vehicle flow control (turn PTO on).
7. Turn on the compressor either at the control box or in the cab and ensure it is in the unloaded state
(check load/unload switch).
8. Turn on the unload/load switch to load and see if the compressor builds pressure to the regulated
setting.
9. Plug an air tool into the air outlet and operate. Ensure that the compressor works as required.
10. When the work is finished, switch the compressor to unload.
11. It is good practice to allow the compressor to run under no load for 2-3 minutes.
12. Switch off at either the control box or in Cab and switch off the vehicle.
13. It is good practice to check for any visible signs of hydraulic fluid leakage and or compressor fluid
leakage after each use.
WARNING

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4. INSTALLATION
The SMARTPACK 180H is designed as an integrated compressor system for connection to an existing
hydraulic system. The following table can be used as a reference when setting up the compressor
Hydraulic Oil Flow required.
WARNING When setting up the Compressor unit, ensure there is a safety mechanism in
place to prevent any excessive flow or pressure into the compressor hydraulic circuit.
MEA will not warrant any damage caused to the compressor and will void warranty due to
inadequate safety protection of the existing hydraulic system.
1. Install SMARTPACK 180H into position on the vehicle using 6 x min. M12 x 1.75 Grade 8.8
Fasteners.
2. Install the hydraulic lines “P” pressure line “T” tank/return line “D” case drain if required. This is
to ensure compressor rotation is correct.
3. If purchasing the Frameless version only; install the cooler and connect the compressor cooler lines to
both the cooler and the compressor.
4. Connect the electrical control box to the vehicle; be sure to place an in-line weatherproof
fuse (30A –12V and 20A –24V) within 300mm of the vehicle battery. Ensure the control box
is compatible with your vehicle’s voltage rating.
5. Connect the pressure gauge line to the SMARTPACK 180H, see circuit diagram.
6. Connect the terminals of the electrical loom as per the circuit diagram relevant to your
vehicle to both the vehicle and the SMARTPACK 180H.
7. Check the level of oil in the compressor.
8. Switch on the vehicle, turn on the compressor at the control box and test the hydraulic
solenoid for operation.
9. Turn the unload/load switch to load and check the compressor builds pressure to the
regulated pressure setting.
10. Plug an air tool into the air outlet and operate checking that the compressor works as
required, run for 10mins.
11. Unload the compressor, switch off the control box, switch off the vehicle and check for any
visible signs of hydraulic fluid leakage.
12. When cool (safe to touch), and switched off, re-check compressor oil level.
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 SEPARATOR INLET.

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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.
Interval
Compressor
ACTION TO BE TAKEN
Periodically During Operation
Observe all gauge readings. Note any change from the
normal readings 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.)
Periodically or as required
Inspect and replace spin-on coalescing element if necessary.
Inspect and clean oil cooler fins.
Check system for oil and/or air leaks.
Every 10 Hours or Daily
Check the compressor oil level.
Check air filter/s and connecting hose and clamps.
Check for oil and air system, including hoses, for leaks.
Every 25 Hours or Monthly
Drain water from tank and check Compressor oil level.
After first 50 hours of operation
Check system for oil and/or air leaks.
Check engine/compressor mounts fastener torque.
Check belt and pulleys for signs of wear - note that belt
normally gives off blue particles until it runs in.
Every 100 Hours
Check compressor oil level.
Clean air cleaner element.
Check engine/compressor/generator mounts for excessive
wear and fastener torque.
Every 400 Hours of operation or 9
months (See Service Kit List)
Change compressor oil approx. 7L.
Change compressor oil filter.
Change compressor air filter.
Check belt and pulleys for signs of wear.
Check valve clearance.
800 Hours / 18 months
Change compressor coalescing filter.

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6. SPARE PARTS AND SERVICE KITS

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Part Number
Description
10008-P0024
AIR FILTER ELEMENT
10008-P0029
SPIN ON COALESCER
10008-P0078
OIL FILTER
10019-K0005
5 LITRE SEMI SYNTHETIC OIL

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7. TROUBLE SHOOTING
SYMPTOMS
PROBABLE CAUSE
CORRECTIVE ACTION
The compressor does not
load.
1-The intake valve remains closed.
1-Check the valve. If necessary, replace the
damaged parts with the spare parts kit.
2-The solenoid valve does not work
accurately
2-Check the solenoid valve. If necessary, replace it.
3-Losses on the pressure line.
3-Check pipes and cables. If necessary, replace
them.
During idling phase, the
compressor does not
discharge pressure from
separator tank
1-The solenoid valve does not work
accurately.
1-Check the solenoid valve. If necessary, replace it.
2-The calibrated nozzle is clogged.
2-Remove the calibrated nozzle. Clean or replace it.
Compressor capacity or
pressure lower than usual
standard.
1-The air filter is clogged.
1-Remove the air filter. Clean or replace it.
2-The intake valve does not open.
2-Check the valve. If necessary, replace the
damaged parts with the spare parts kit.
3-Air loss from safety valve.
3-Replace the valve.
Compressor keeps on
loading over working
pressure: safety valve opens
1-The solenoid valve does not work
accurately.
1-Check the solenoid valve. If necessary, replace it.
2-Clogged separator filter.
2-Replace the separator filter.
Compressor overheating.
1-Insufficient cooling.
1-Check the cooling system. Check coolant level on
tank.
2-Dirty oil
2-Replace it with new oil.
3-Oil level is too low.
3-Check coolant level on tank and if necessary, add
oil.
4-Clogged-up cooler or pipe connection
4-Clean cooler and pipes.
5-The thermostatic valve does not work
correctly.
5-Check the thermostatic valve. If necessary,
replace the damaged parts with K13 spare parts kit
(Contact MEA for parts required)
6-Clogged oil filter
6-Remove the oil filter. Clean or replace it.
During unloading phase,
pressure increases up to
safety
valve opening
1-The intake valve remains open.
1-Check the valve. If necessary, replace the
damaged parts with spare parts kit.
2-The calibrated nozzle is clogged.
2-Remove the calibrated nozzle. Clean or replace it.
Oil leakage from intake
valve only when the
machine is switched off: oil
soaked-up air filter
1-The intake valve does not work properly
(does not close)
1-Check the valve. If necessary, replace the
damaged parts with spare parts kit.
2-The no-return valve of intake valve does
not work correctly.
2-Check it and clean it.
Oil soaked-up air filter during
unloading phase
1-Too high level of oil in the tank
1-Check oil level on separator tank.
2- Clogged separator filter
2- Replace the separator filter.
3-The recovery oil viewer is dirty or does
not work appropriately.
3 -Clean it or if necessary, replace the damaged
parts with K11 spare parts kit.
If separator filter is clogged up, replace it.
The compressor remains
under loading phase.
1-The intake valve does not work properly
(does not close)
1-Check the valve. If necessary, replace the
damaged parts with spare parts kit.
Rotor seizure
1-Unknown particles inside.
1-Call MEA technical support.
2-Insufficient lubrication.
2-Call MEA technical support.
Presence of oil in the outlet
of minimum pressure valve
1-Separator filter damaged.
1-Replace the separator filter.
2-Oil recovery viewer obstructed.
2-Clean the oil recovery viewer.
3-Separator nipple with O-rings damaged.
3-Replace K1 spare parts kit.

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8. DRAWINGS & ILLUSTRATIONS
GENERAL ARRANGEMENT DRAWING

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ELECTRICAL DIAGRAM ( FRAMED)