USER MANUAL

COMPASS CONTROLLER™

PART NUMBER:
02250167-454 R03
KEEP FOR
FUTURE
WARRANTY NOTICE REFERENCE
Failure to follow the instructions ©
COPYRIGHT 2012 SULLAIR
and procedures in this manual or, The information in this manual is current
as of its publication date, and applies to
misuse of this equipement will compressor serial number:
VOID its warranty!
201201010000
and all subsequent serial numbers.
 AIR CARE SEMINAR TRAINING
Sullair Air Care Seminars are courses that provide hands-on instruction for the proper operation, maintenance,
and servicing of Sullair products. Individual seminars on portable compressors and compressor electrical
systems are offered at regular intervals throughout the year at Sullair’s corporate headquarters training facility
located at Michigan City, Indiana.

Instruction includes training on the function and installation of Sullair service parts, troubleshooting common
faults and malfunctions, and actual equipment operation. These seminars are recommended for maintenance,
contractor maintenance, and service personnel.

For detailed course outlines, schedule, and cost information contact:

SULLAIR TRAINING DEPARTMENT

1-888-SULLAIR or
219-861-5623
www.sullair.com
training@sullair.com
- Or Write -
Sullair
3700 E. Michigan Blvd.
Michigan City, IN 46360
Attn: Service Training Department.
 TABLE OF CONTENTS
SECTION 1—SAFETY
5 1.1 GENERAL
5 1.2 TOWING
8 1.3 PRESSURE RELEASE
9 1.4 FIRE AND EXPLOSION
10 1.5 MOVING PARTS
11 1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNERS
11 1.7 TOXIC AND IRRITATING SUBSTANCES
12 1.8 ELECTRICAL SHOCK
12 1.9 LIFTING
13 1.10 ENTRAPMENT
13 1.11 JUMP STARTING
14 1.12 IMPLEMENTATION OF LOCKOUT/TAGOUT
15 1.13 CALIFORNIA PROPOSITION 65
16 1.14 SYMBOLS AND REFERENCES

SECTION 2—STARTUP PROCEDURES

19 2.1 INTRODUCTION
19 2.2 CONTROLLER PANEL LAYOUT
19 2.3 COMPASS CONTROLLER POWER UP
21 2.4 NORMAL OPERATION

SECTION 3—ADJUSTMENTS
23 3.1 INTRODUCTION
23 3.2 SETTINGS AND DIAGNOSTIC
30 3.3 CONFIGURATION MENU
32 3.4 USER ADJUSTABLE CONTROL PARAMETERS (UCP)

SECTION 4—DESCRIPTION
35 4.1 INTRODUCTION
35 4.2 OPERATING MODES
TABLE OF CONTENTS

41 4.3 COMPRESSOR SHUTDOWN

SECTION 5—TROUBLESHOOTING
45 5.1 TROUBLESHOOTING INTRODUCTION
45 5.2 TROUBLESHOOTING GUIDE INTRODUCTION
46 5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE
 Section 1
SAFETY
NOTE
OPERATOR IS REQUIRED TO READ
ENTIRE INSTRUCTION MANUAL.
1.1 GENERAL
Sullair designs and manufactures all of its products
so they can be operated safely. However, the
responsibility for safe operation rests with those who
use and maintain these products. The following
safety precautions are offered as a guide which, if
conscientiously followed, will minimize the possibility
of accidents throughout the useful life of this
equipment. Read the CIMA Safety Manual prior to
compressor operation and towing, if applicable
in your area.
The air compressor should be operated only by those
who have been trained and delegated to do so, and
who have read and understood this Operator’s
Manual. Failure to follow the instructions, procedures
and safety precautions in this manual can result in
accidents and injuries.
NEVER start the air compressor unless it is safe to
do so. DO NOT attempt to operate the air
compressor with a known unsafe condition. Tag the
air compressor and render it inoperative by
disconnecting the battery so others who may not
know of the unsafe condition will not attempt to
operate it until the condition is corrected.
Use and operate the air compressor only in full
compliance with all pertinent OSHA requirements
(I) WHILE NOT TOWED IN THE USUAL SENSE OF THE WORD, MANY OF THESE INSTRUCTIONS ARE DIRECTLY APPLICABLE TO SKID-MOUNTED
PORTABLE AIR COMPRESSORS AS WELL.
and/or all pertinent Federal, State and Local codes or
requirements.
DO NOT modify the compressor except with written
factory approval.
Each day, walk around the air compressor and
inspect for leaks, loose or missing parts, damaged
parts or parts out of adjustment. Perform all
recommended daily maintenance.
Inspect for torn, frayed, blistered or otherwise
deteriorated and degraded hoses. Replace as
required.
CAUTION
Estimated hose life based on a 5-day 8-hour
work week is 3 years. These conditions
exist on an 8-hour shift only. Any other
operation of the equipment other than 8-
hour shifts would shorten the hose life
based on hours of operation.
1.2 TOWING (I)
PREPARING TO TOW
WARNING
Do NOT tow the compressor should its
weight exceed the rated limit of the tow
vehicle, as the vehicle may not brake safely
with excess weight. See rated limit in tow
vehicle Operator's Manual, and review its
instructions and other requirements for
safe towing.
5

A. Prior to hitching the air compressor to the tow
vehicle, inspect all attachment parts and equip-
ment, checking for (i) signs of excessive wear or
corrosion, (ii) parts that are cracked, bent,
dented or otherwise deformed or degraded, and
(iii) loose nuts, bolts or other fasteners. Should
any such condition be present, DO NOT TOW
until the problem is corrected.
B. Back the tow vehicle to the compressor and posi-
tion it in preparation for coupling the compressor.
C. If the compressor is provided with a drawbar
latched in the vertical upright position, carefully
unlatch drawbar and lower it to engage the cou-
pling device. If not, raise drawbar with the jack to
engage coupling device or otherwise couple the
compressor to the towing vehicle.
WARNING
This equipment may be tongue heavy. DO
NOT attempt to raise or lower the drawbar
by hand if the weight is more than you can
safely handle.
Use the screw jack provided or a chain fall
if you cannot lift or lower it without avoiding
injury to yourself or others. Keep hands
and fingers clear of the coupling device and
all other pinch points. Keep feet clear of
drawbar to avoid injury in case it should
slip from your hands.
D. Make sure the coupling device is fully engaged,
closed and locked.
E. If chains are provided, pass each chain through
its point of attachment on the towing vehicle;
then hook each chain to itself by passing the
grab hook over (not through) a link. Cross chains
under the front of drawbar before passing them
through points of attachment on towing vehicle to
support the front of drawbar in case it should
accidentally become uncoupled.
F. Make sure that the coupling device and adjacent
structures on the towing vehicle (and also, if uti-
lized, chain adjustment, brake and/or electrical
interconnections) DO NOT interfere with or
restrict motion of any part of the compressor,
including its coupling device, with respect to the
towing vehicle when maneuvering over any
anticipated terrain.
6
SECTION 1
G. If provided, make sure chain length, brake and
electrical interconnections provide sufficient
slack to prevent strain when cornering and
maneuvering, yet are supported so they cannot
drag or rub on road, terrain or towing vehicle sur-
faces which might cause wear that could render
them inoperative.
WARNING
This equipment may be tongue heavy. DO
NOT attempt to raise or lower the drawbar
by hand if the weight is more than you can
safely handle.
CAUTION
Retract the front screw jack only after
attaching the compressor to the tow vehi-
cle. Raise the screw jack to its full up posi-
tion and pull the pin connecting the jack to
the drawbar. Rotate the screw jack to its
stowed position, parallel to the drawbar,
and reinsert the pin. Make sure the jack is
secured in place prior to towing.
If a caster wheel is provided on the screw
jack it is part of the screw jack and can not
be removed. Follow the same procedure for
stowing away the wheeled jack as you
would for the standard screw jack. Pull the
pin connecting the jack to the drawbar and
raise the screw jack to its full up position.
Rotate the screw jack to its stowed posi-
tion, parallel to the drawbar, and reinsert
the pin. Make sure the jack is secured in
place prior to towing.
H. On two-wheeled models, fully retract front screw
jack and any rear stabilizer legs. If a caster wheel
is provided on the screw jack it is part of the
screw jack, and can not be removed. Follow the
same procedure for stowing away the wheeled
jack as you would for the standard screw jack.
Pull the pin connecting the jack to the drawbar
and raise the screw jack to its full upright posi-
tion. Rotate the screw jack to its stowed position,
parallel to the drawbar, and reinsert the pin.
Make sure the jack is secured in place prior to
towing.
SECTION 1
I. Make sure tires are in good condition and are the
size (load range) specified and are inflated to the
specified pressures. DO NOT change the tire
size or type. Also, make sure wheel bolts, lugs or
nuts are tightened to the specified torques.
J. If provided, make sure all dual stop, tail direc-
tional and clearance lights are operating properly
and that their lenses are clean and functional.
Also, make sure all reflectors and reflecting sur-
faces, including the slow moving vehicle emblem
on compressors provided with same, are clean
and functional.
K. Make sure all service air hoses (not air brake
hoses) are disconnected or are fully stowed and
secured on hose reels, if provided.
L. Make sure all access doors and tool box covers
are closed and latched. If the compressor is
large enough to hold a man, make sure all per-
sonnel are out before closing and latching
access doors.
M. Make sure parking brakes in towing vehicle are
set, or that its wheels are chocked or blocked, or
that it is otherwise restrained from moving. Then,
release the compressor parking brakes, if pro-
vided.
N. Make sure the compressor wheels are not
chocked or blocked, and that all tie-downs, if any,
are free.
O. Test running brake operation, including break-
away switch operation if provided, before
attempting to tow the compressor at its rated
speed or less when conditions prevail.
P. DO NOT carry loose or inappropriate tools,
equipment or supplies on or in the compressor.
Q. DO NOT load this equipment with accessories or
tools such that it is unbalanced from side to side
or front to back. Such unbalance will reduce the
towability of this equipment and may increase
the possibility of tipping, rolling over, jackknifing,
etc. Loss of control of the towing vehicle may
result.
TOWING
A. Observe all Federal, State, and Local laws while
towing this equipment (including those specifying
minimum speed).
B. DO NOT exceed the towing speeds listed below
under ideal conditions. Reduce your speed
according to posted speed limits, weather, traffic,
road or terrain conditions:
1. Two axle four-wheel or three axle six-wheel
steerable models: 15 MPH (24 km/h).
2. All other models: 55 MPH (88 km/h).
C. Remember that the portable air compressor may
approach or exceed the weight of the towing
vehicle. Maintain increased stopping distances
accordingly. DO NOT make sudden lane
changes, U-turns or other maneuvers. Such
maneuvers can cause the compressor to tip, roll
over, jackknife or slide and cause loss of control
of the towing vehicle. Tipping, rolling over, etc.
can occur suddenly without warning. U-turns
especially should be made slowly and carefully.
D. Avoid grades in excess of 15° (27%).
E. Avoid potholes, rocks and other obstructions,
and soft shoulders or unstable terrain.
F. Maneuver in a manner that will not exceed the
freedom of motion of the compressor’s drawbar
and/ or coupling device, in or on the towing vehi-
cle’s coupling device and/or adjacent structure
whether towing forward or backing up, regard-
less of the terrain being traversed.
G. DO NOT permit personnel to ride in or on the
compressor.
H. Make sure the area behind, in front of, and under
the compressor is clear of all personnel and
obstructions prior to towing in any direction.
I. DO NOT permit personnel to stand or ride on the
drawbar, or to stand or walk between the com-
pressor and the towing vehicle.
PARKING OR LOCATING COMPRESSOR
A. Park or locate compressor on a level surface, if
possible. If not, park or locate compressor across
grade so the compressor does not tend to roll
downhill. DO NOT park or locate compressor on
grades exceeding 15° (27%).
B. Make sure compressor is parked or located on a
firm surface that can support its weight.
C. Park or locate compressor so the wind, if any,
tends to carry the exhaust fumes and radiator
heat away from the compressor air inlet open-
ings, and also where the compressor will not be
exposed to excessive dust from the work site.
D. On steerable models, park compressor with front
wheels in straight-ahead position.
7

E. Set parking brakes and disconnect breakaway
switch cable and all other interconnecting electri-
cal and/or brake connections, if provided.
F. Block or chock both sides of all wheels.
G. If provided, unhook chains and remove them
from the points of chain attachment on the towing
vehicle, then hook chains to bail on drawbar or
wrap chains around the drawbar and hook them
to themselves to keep chains off the ground
which might accelerate rusting.
H. Lower front screw jack and/or any front and rear
stabilizer legs. Make sure the surface they con-
tact has sufficient load bearing capability to sup-
port the weight of the compressor.
WARNING
This equipment may be tongue heavy. DO
NOT attempt to raise or lower the drawbar
by hand if the weight is more than you can
safely handle.
CAUTION
Retract the front screw jack only after
attaching the compressor to the tow vehi-
cle. Raise the screw jack to its full up posi-
tion and pull the pin connecting the jack to
the drawbar. Rotate the screw jack to its
stowed position, parallel to the drawbar,
and reinsert the pin. Make sure the jack is
secured in place prior to towing.
On two-wheeled models, fully retract front
screw jack and any rear stabilizer legs. If a
caster wheel is provided on the screw jack
it is part of the screw jack and can not be
removed. Follow the same procedure for
stowing away the wheeled jack as you
would for the standard screw jack. Pull the
pin connecting the jack to the drawbar and
raise the screw jack to its full up position.
Rotate the screw jack to its stowed posi-
tion, parallel to the drawbar, and reinsert
the pin. Make sure the jack is secured in
place prior to towing.
I. If a caster wheel is provided on the screw jack, it
is part of the screw jack and cannot be removed.
Follow the same procedure for stowing away the
8
SECTION 1
wheeled jack as you would for the standard screw
jack. Raise the screw jack to its full upright posi-
tion and pull the pin connecting the jack to the
drawbar. Rotate the screw jack to its stowed posi-
tion, parallel to the drawbar and reinsert the pin.
Make sure the jack is secured in place prior to
towing.
J. Disconnect coupling device, keeping hands and
fingers clear of all pinch points. If the compressor
is provided with a drawbar, DO NOT attempt to lift
the drawbar or if hinged, to raise it to the upright
position by hand, if the weight is more than you
can safely handle. Use a screwjack or chain fall if
you cannot lift or raise the drawbar without avoid-
ing injury to yourself or others.
K. Move the towing vehicle well clear of the parked
compressor and erect hazard indicators, barri-
cades and/or flares (if at night) if compressor is
parked on or adjacent to public roads. Park so as
not to interfere with traffic.
NOTE
While not towed in the usual sense of the
word, many of these instructions are
directly applicable to skidmounted porta-
ble air compressors as well.
1.3 PRESSURE RELEASE
A. Open the pressure relief valve at least weekly to
make sure it is not blocked, closed, obstructed or
otherwise disabled.
B. Install an appropriate flow-limiting valve between
the compressor service air outlet and the shutoff
(throttle) valve, when an air hose exceeding 1/2"
(13 mm) inside diameter is to be connected to the
shutoff (throttle) valve, to reduce pressure in case
of hose failure, per OSHA Standard 29 CFR
1926.302 (b) (7) or any applicable Federal, State
and Local codes, standards and regulations.
C. When the hose is to be used to supply a manifold,
install an additional appropriate flow-limiting valve
between the manifold and each air hose exceed-
ing 1/2" (13 mm) inside diameter that is to be con-
nected to the manifold to reduce pressure in case
of hose failure.
D. Provide an appropriate flow-limiting valve for each
additional 75 feet (23 m) of hose in runs of air
hose exceeding 1/2" (13 mm) inside diameter to
reduce pressure in case of hose failure.
SECTION 1
E. Flow-limiting valves are listed by pipe size and
rated CFM. Select appropriate valve accordingly.
F. DO NOT use tools that are rated below the maxi-
mum rating of this compressor. Select tools, air
hoses, pipes, valves, filters and other fittings
accordingly. DO NOT exceed manufacturer’s
rated safe operating pressures for these items.
G. Secure all hose connections by wire, chain or
other suitable retaining device to prevent tools or
hose ends from being accidentally disconnected
and expelled.
H. Open fluid filler cap only when compressor is not
running and is not pressurized. Shut down the
compressor and bleed the sump (receiver) to
zero internal pressure before removing the cap.
I. Vent all internal pressure prior to opening any
line, fitting, hose, valve, drain plug, connection or
other component, such as filters and line oilers,
and before attempting to refill optional air line
anti-icer systems with antifreeze compound.
J. Keep personnel out of line with and away from
the discharge opening of hoses, tools or other
points of compressed air discharge.
K. DO NOT use air at pressures higher than 30 psig
(2.1 bar) for cleaning purposes, and then only
with effective chip guarding and personal protec-
tive equipment per OSHA Standard 29 CFR
1910.242 (b) or any applicable Federal, State
and Local codes, standards and regulations.
L. DO NOT engage in horseplay with air hoses as
death or serious injury may result.
M. This equipment is supplied with an ASME
designed pressure vessel protected by an ASME
rated relief valve. Lift the handle once a week to
make sure the valve is functional. DO NOT lift
the handle while machine is under pressure.
N. If the machine is installed in an enclosed area it
is necessary to vent the relief valve to the outside
of the structure or to an area of non-exposure.
O. DO NOT remove radiator filler cap until the cool-
ant temperature is below its boiling point. Then
loosen cap slowly to its stop to relieve any
excess pressure and make sure coolant is not
boiling before removing cap completely. Remove
radiator filler cap only when cool enough to touch
with a bare hand.
P. The ethyl ether in the replaceable cylinders used
in diesel ether starting aid systems (optional) is
under pressure. DO NOT puncture or incinerate
those cylinders. DO NOT attempt to remove the
center valve core or side pressure relief valve
from these cylinders regardless of whether they
are full or empty.
Q. If a manual blowdown valve is provided on the
receiver, open the valve to ensure all internal
pressure has been vented prior to servicing any
pressurized component of the compressor air/
fluid system.
1.4 FIRE AND EXPLOSION
WARNING
Do not attempt to operate the compressor
in any classification of hazardous environ-
ment or potentially explosive atmosphere
unless the compressor has been specially
designed and manufactured for that duty.
A. Refuel at a service station or from a fuel tank
designed for its intended purpose. If this is not
possible, ground the compressor to the dis-
penser prior to refueling.
B. Clean up spills of fuel, fluid, battery electrolyte or
coolant immediately if such spills occur.
C. Shut off air compressor and allow it to cool. Then
keep sparks, flames and other sources of ignition
away and DO NOT permit smoking in the vicinity
when adding fuel, checking or adding electrolyte
to batteries, checking or adding fluid, checking
diesel engine ether starting aid systems, replac-
ing cylinders, or when refilling air line anti-icer
systems antifreeze compound.
D. DO NOT permit liquids, including air line anti-icer
system antifreeze compound or fluid film, to
accumulate on bottom covers or on, under or
around acoustical material, or on any external or
internal surfaces of the air compressor. Wipe
down using an aqueous industrial cleaner or
steam clean as required. If necessary, remove
acoustical material, clean all surfaces and then
replace acoustical material. Any acoustical mate-
rial with a protective covering that has been torn
or punctured should be replaced immediately to
prevent accumulation of liquids or fluid film within
the material. DO NOT use flammable solvents
for cleaning purposes.
9

E. Disconnect the grounded (negative) battery con-
nection prior to attempting any repairs or clean-
ing inside the enclosure. Tag the battery
connections so others will not unexpectedly
reconnect it.
F. Keep electrical wiring, including the battery ter-
minals and other terminals, in good condition.
Replace any wiring that has cracked, cut
abraded or otherwise degraded insulation or ter-
minals that are worn, discolored or corroded.
Keep all terminals clean and tight.
G. Turn off battery charger before making or break-
ing connections to the battery.
H. Keep grounded conductive objects such as tools
away from exposed live electrical parts such as
terminals to avoid arcing which might serve as a
source of ignition.
I. Replace damaged fuel tanks or lines immediately
rather than attempt to weld or otherwise repair
them. DO NOT store or attempt to operate the
compressor with any known leaks in the fuel sys-
tem. Tag the compressor and render it inopera-
tive until repair can be made.
J. Remove any acoustical material or other material
that may be damaged by heat or that may sup-
port combustion prior to attempting weld repairs.
Remove diesel engine ether starting aid cylin-
ders and air line anti-icer system components
containing antifreeze compound, prior to
attempting weld repairs in any place other than
the fuel system. DO NOT weld on or near the
fuel system.
K. Keep a suitable, fully charged class BC or ABC
fire extinguisher or extinguishers nearby when
servicing and operating the compressor.
L. Keep oily rags, trash, leaves, litter or other com-
bustibles out of and away from the compressor.
M. Open all access doors and allow the enclosure to
ventilate thoroughly prior to attempting to start
the engine.
N. DO NOT operate compressor under low over-
hanging leaves or permit such leaves to contact
hot exhaust system surfaces when operating the
compressor in forested areas.
O. Ethyl ether used in diesel engine ether starting
aid systems is extremely flammable. Change cyl-
inders, or maintain or troubleshoot these sys-
tems only in well-ventilated areas away from
10
SECTION 1
heat, open flame or sparks. DO NOT install,
store or otherwise expose ether cylinders to tem-
peratures above 160 °F (71 °C). Remove ether
cylinder from the compressor when operating in
ambient temperatures above 60 °F (16 °C).
P. DO NOT attempt to use ether as a starting aid in
gasoline engines or diesel engines with glow
plugs as serious personnel injury or property
damage may result.
Q. DO NOT spray ether into compressor air filter or
into an air filter that serves both the engine and
the compressor as serious damage to the com-
pressor or personal injury may result.
R. Antifreeze compound used in air line anti-icer
systems contains methanol which is flammable.
Use systems and refill with compound only in
well-ventilated areas away from heat, open
flames or sparks. DO NOT expose any part of
these systems or the antifreeze compound to
temperatures above 150 °F (66 °C). Vapors from
the antifreeze compound are heavier than air.
DO NOT store compound or discharge treated
air in confined or unventilated areas. DO NOT
store containers of antifreeze compound in direct
sunlight.
S. Store flammable fluids and materials away from
your work area. Know where fire extinguishers
are and how to use them, and for what type of
fire they are intended. Check readiness of fire
suppression systems and detectors if so
equipped.
1.5 MOVING PARTS
A. Keep hands, arms and other parts of the body
and also clothing away from belts, pulleys and
other moving parts.
B. DO NOT attempt to operate the compressor with
the fan or other guards removed.
C. Wear snug-fitting clothing and confine long hair
when working around this compressor, especially
when exposed to hot or moving parts inside the
enclosure.
D. Keep access doors closed except when making
repairs or adjustments, performing service or
when starting or stopping the compressor.
E. Make sure all personnel are out of the way and
clear of the compressor prior to attempting to
start or operate it.
SECTION 1
F. Shut off engine before adding fuel, fluid, coolant
lubricants, air line antifreeze compound or bat-
tery electrolyte, or before replacing ether starting
aid cylinders.
G. Disconnect the grounded negative battery con-
nection to prevent accidental engine operation
prior to attempting repairs or adjustments. Tag
the battery connection so others will not unex-
pectedly reconnect it.
H. When adjusting the controls, it may require oper-
ation of the equipment during adjustment. DO
NOT come in contact with any moving parts
while adjusting the control regulator and setting
the engine RPM. Make all other adjustments with
the engine shut off. When necessary, make
adjustment, other than setting control regulator
and engine RPM, with the engine shut off. If nec-
essary, start the engine and check adjustment. If
adjustment is incorrect, shut engine off, readjust,
then restart the engine to recheck adjustment.
I. Keep hands, feet, floors, controls and walking
surfaces clean and free of fluid, water, antifreeze
or other liquids to minimize possibility of slips and
falls.
1.6 HOT SURFACES, SHARP
EDGES AND SHARP
CORNERS
A. Avoid bodily contact with hot fluid, hot coolant,
hot surfaces and sharp edges and corners.
B. Keep all parts of the body away from all points of
air discharge and away from hot exhaust gases.
C. Wear personal protective equipment including
gloves and head covering when working in, on or
around the compressor.
D. Keep a first aid kit handy. Seek medical assis-
tance promptly in case of injury. DO NOT ignore
small cuts and burns as they may lead to infec-
tion.
1.6.1 TIER 4 EMISSIONS MODULE
General Guidelines: Thermal Protection. The main
exhaust piping routes exhaust gas from the engine to
the Clean Emissions Module (CEM). Normal
operating temperatures can reach up to 530 °C (986
°F). During regeneration of the Diesel Particulate
Filter (DPF), the Auxiliary Regeneration Device
(ARD) will be in operation, this creating temperatures
above normal engine exhaust temperatures. Gas
temperatures during the regeneration period can
reach 750 °C (1382 °F).
WARNING
Increased DPF skin temperature and
exhaust gas temperature may occur in the
event of an unexpected engine/aftertreat-
ment failure. An unexpected failure of the
engine/aftertreatment may increase temper-
ature at the DPF as high as 900 °C (1652 °F)
gas temperature and 750 °C (1382 °F) skin
temperature. This may result in fire, burn, or
explosion hazards, which may result in per-
sonal injury or death. Do not expose flam-
mable material or explosive atmospheres to
exhaust gas or exhaust system components
during regeneration. The aftertreatment skin
temperature and the gas temperature are
difficult to measure and/or simulate and are
dependent upon many factors including the
following: the nature of the engine/after-
treatment failure, the design and packaging
of the aftertreatment, the engine speed/load
conditions, the condition of the aftertreat-
ment and ambient conditions. Therefore,
the potential temperatures are provided as a
guideline even under conditions of unex-
pected engine and/or aftertreatment failure.
Proper precautions should be taken to
ensure that the aftertreatment device is not
mounted in close proximity to components
that may be damaged by heat.
11

1.7 TOXIC AND IRRITATING
SUBSTANCES
A. DO NOT use air from this compressor for respi-
ration (breathing) except in full compliance with
OSHA Standards 29 CFR 1920 and any other
Federal, State or Local codes or regulations.
DANGER
INHALATION HAZARD!
Death or serious injury can result from
inhaling compressed air without using
proper safety equipment. See OSHA stan-
dards and/or any applicable Federal, State,
and Local codes, standards and regulations
on safety equipment.
B. DO NOT use air line anti-icer systems in air lines
supplying respirators or other breathing air utili-
zation equipment and DO NOT discharge air
from these systems into unventilated or other
confined areas.
C. Operate the compressor only in open or well-
ventilated areas.
D. If the compressor is operated indoors, discharge
engine exhaust fumes outdoors.
E. Locate the compressor so that exhaust fumes
are not apt to be carried towards personnel, air
intakes servicing personnel areas or towards the
air intake of any portable or stationary compres-
sor.
F. Fuels, fluids, coolants, lubricants and battery
electrolyte used in the compressor are typical of
the industry. Care should be taken to avoid acci-
dental ingestions and/or skin contact. In the
event of ingestion, seek medical treatment
promptly. DO NOT induce vomiting if fuel is
ingested. Wash with soap and water in the event
of skin contact.
G. Wear an acid-resistant apron and a face shield or
goggles when servicing the battery. If electrolyte
12
SECTION 1
is spilled on skin or clothing, immediately flush
with large quantities of water.
H. Ethyl ether used in diesel engine ether starting
aid systems is toxic, harmful or fatal if swallowed.
Avoid contact with the skin or eyes and avoid
breathing the fumes. If swallowed, DO NOT
induce vomiting and call a physician immediately.
I. Wear goggles or a full face shield when testing
ether starting aid systems or when adding anti-
freeze compound to air line anti-icer systems.
Keep openings of valve or atomizer tube of ether
starting aid system pointed away from yourself
and other personnel.
J. If ethyl ether or air line anti-icer system anti-
freeze compound enters the eyes or if fumes irri-
tate the eyes, they should be washed with large
quantities of clean water for 15 minutes. A physi-
cian, preferably any eye specialist, should be
contacted immediately.
K. DO NOT store ether cylinders or air line anti-icer
system antifreeze compound in operator’s cabs
or in other similar confined areas.
L. The antifreeze compound used in air line anti-
icer systems contains methanol and is toxic,
harmful or fatal if swallowed. Avoid contact with
the skin or eyes and avoid breathing the fumes. If
swallowed, induce vomiting by administering a
tablespoon of salt in a glass of clean warm water.
Do this until vomit is clear, then administer two
tablespoons of baking soda in a glass of clean
water. Have patient lay down and cover eyes to
exclude light. Call a physician immediately.
1.8 ELECTRICAL SHOCK
A. Keep the towing vehicle or equipment carrier,
compressor hoses, tools and all personnel at
least 10 feet (3 m) from power lines and buried
cables.
B. Keep all parts of the body and any hand-held
tools or other conductive objects away from
exposed live parts of electrical system. Maintain
dry footing, stand on insulating surfaces and DO
NOT contact any other portion of the compressor
when making adjustments or repairs to exposed
live parts of the electrical system.
C. Attempt repairs only in clean, dry and well-lighted
and ventilated areas.
D. Stay clear of the compressor during electrical
storms! It can attract lightning.
SECTION 1
1.9 LIFTING
A. If the compressor is provided with a lifting bail,
then lift by the bail provided. If no bail is provided,
then lift by sling. Compressors to be air lifted by
helicopter must not be supported by the lifting
bail, but by slings instead. In any event, lift only in
full compliance with OSHA Standards 29 CFR
1910 subpart N or any other Local, State, Military
and Federal regulations that may apply.
B. Inspect lifting bail and points of attachment for
cracked welds and for cracked, bent, corroded or
otherwise degraded members and for loose bolts
or nuts prior to lifting.
C. Make sure entire lifting, rigging and supporting
structure has been inspected, is in good condi-
tion and has a rated capacity of at least the net
weight of the compressor plus an additional 10%
allowance for weight of water, snow, ice, mud,
stored tools, and equipment. If your are unsure
of the weight, then weigh compressor before lift-
ing.
D. Make sure lifting hook has a functional safety
latch or equivalent, and is fully engaged and
latched on the bail.
E. Use guide ropes or equivalent to prevent twisting
or swinging of the compressor once it has been
lifted clear of the ground.
F. DO NOT attempt to lift in high winds.
G. Keep all personnel out from under and away
from the compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendance when-
ever compressor is suspended.
J. Set compressor down only on a level surface
capable of supporting at least its net weight plus
an additional 10% allowance for the weight of
water, snow, ice, mud, stored tools, and/or equip-
ment.
K. If the compressor is provided with parking
brakes, make sure they are set, and in any
event, block or chock both sides of all running
wheels before disengaging the lifting hook.
1.10 ENTRAPMENT
A. Make sure all personnel are out of compressor
before closing and engaging enclosure doors.
B. If the compressor is large enough to hold a man
and if it is necessary to enter it to perform service
adjustments, inform other personnel before
doing so, or else secure the access door in the
open position to avoid the possibility of others
closing and possibly latching the door with per-
sonnel inside.
1.11 JUMP STARTING
A. Observe all safety precautions mentioned else-
where in this manual.
B. Batteries may contain hydrogen gas which is
flammable and explosive. Keep flames, sparks
and other sources of ignition away.
C. Batteries contain acid which is corrosive and poi-
sonous. DO NOT allow battery acid to contact
eyes, skin, fabrics or painted surfaces as serious
personal injury or property damage could result.
Flush any contacted areas thoroughly with water
immediately. Always wear an acid-resistant
apron and face shield when attempting to jump
start the compressor.
D. Remove all vent caps (if so equipped) from the
battery or batteries in the compressor. DO NOT
permit dirt or foreign matter to enter the open
cells.
E. Check fluid level. If low, bring fluid to proper level
before attempting to jump start (not applicable to
maintenance-free batteries).
F. DO NOT attempt to jump start if fluid is frozen or
slushy. Bring batteries up to at least 60 °F (16
°C) before attempting to jump start or it may
explode.
G. Cover open cells of all compressor batteries with
clean dampened cloths before attempting to
jump start.
H. Attempt to jump start only with a vehicle having a
negative ground electrical system with the same
voltage, and is also equipped with a battery or
batteries of comparable size or larger than sup-
plied in the compressor. DO NOT attempt to
jump start using motor generator sets, welders or
other sources of DC power as serious damage
may result.
13

I. Bring the starting vehicle alongside the compres-
sor, but DO NOT permit metal to metal contact
between the compressor and the starting vehicle.
J. Set the parking brakes of both the compressor (if
provided) and the starting vehicle or otherwise
block both sides of all wheels.
K. Place the starting vehicle in neutral or park, turn
off all non-essential accessory electrical loads
and start its engine.
L. Use only jumper cables that are clean, in good
condition and are heavy enough to handle the
starting current.
M. Avoid accidental contact between jumper cable
terminal clips or clamps and any metallic portion
of either the compressor or the starting vehicle to
minimize the possibility of uncontrolled arcing
which might serve as a source of ignition.
N. Positive battery terminals are usually identified
by a plus (+) sign on the terminal and the letters
POS adjacent to the terminal. Negative battery
terminals are usually identified by the letters
NEG adjacent to the terminal or a negative (-)
sign.
O. Connect one end of a jumper cable to the posi-
tive (POS) (+) battery terminal in the starting
vehicle. When jump starting 24V compressors
and if the starting vehicle is provided with two (2)
12V batteries connected in series, connect the
jumper cable to the positive (POS) (+) terminal of
the ungrounded battery.
P. Connect the other end of the same jumper cable
to the positive (POS) (+) terminal of the starter
motor battery in the compressor when jump start-
ing 24V compressors, to the positive (POS) (+)
terminal of the ungrounded battery in the com-
pressor.
Q. Connect one end of the other jumper cable to the
grounded negative (NEG) (-) terminal of the bat-
tery in the starting vehicle. When jump starting
24V compressors and if the starting vehicle is
provided with two (2) 12V batteries connected in
series, connect the jumper cable to the negative
(NEG) (-) terminal of the grounded battery.
R. Check your connections. DO NOT attempt to
start a 24V compressor with one 12V battery in
the starting vehicle. DO NOT apply 24V to one
12V battery in the compressor.
S. Connect the other end of this same jumper cable
to a clean portion of the compressor engine
14
SECTION 1
block away from fuel lines, the crank case
breather opening and the battery.
T. Start the compressor in accordance with normal
procedure. Avoid prolonged cranking.
U. Allow the compressor to warm up. When the
compressor is warm and operating smoothly at
normal idle RPM, disconnect the jumper cable
from the engine block in the compressor, then
disconnect the other end of this same cable from
the grounded negative (NEG) (-) terminal of the
battery in the starting vehicle. Then disconnect
the other jumper cable from the positive (POS)
(+) terminal of the battery in the compressor, or if
provided with two (2) 12V batteries connected in
series, from the ungrounded battery in the com-
pressor, and finally, disconnect the other end of
this same jumper cable from the positive (POS)
(+) terminal of the battery in the starting vehicle
or from the positive (POS) (+) terminal of the
ungrounded battery in the starting vehicle, if it is
provided with two (2) 12V batteries connected in
series.
V. Remove and carefully dispose of the dampened
cloths, as they may now be contaminated with
acid, then replace all vent caps.
1.12 IMPLEMENTATION OF
LOCKOUT/TAGOUT
The energy control procedure defines actions
necessary to lockout a power source of any machine
to be repaired, serviced or set-up, where unexpected
motion, or an electrical or other energy source, would
cause personal injury or equipment damage. The
power source on any machine shall be locked out by
each employee doing the work except when motion
is necessary during setup, adjustment or trouble-
shooting.
A. The established procedures for the application of
energy control shall cover the following elements
and actions and shall be initiated only by Autho-
rized Persons and done in the following
sequence:
1. Review the equipment or machine to be
locked and tagged out.
2. Alert operator and supervisor of which
machine is to be worked on, and that power
and utilities will be turned off.
3. Check to make certain no one is operating
the machine before turning off the power.
SECTION 1
4. Turn off the equipment using normal
shutdown procedure.
5. Disconnect the energy sources:
a. Air and hydraulic lines should be bled,
drained and cleaned out. There should
be no pressure in these lines or in the
reservoir tanks. Lockout or tag lines or
valves.
b. Any mechanism under tension or pres-
sure, such as springs, should be
released and locked out or tagged.
c. Block any load or machine part prior to
working under it.
d. Electrical circuits should be checked with
calibrated electrical testing equipment
and stored energy and electrical capaci-
tors should be safely discharged.
6. Lockout and/or Tagout each energy source
using the proper energy isolating devices
and tags. Place lockout hasp and padlock or
tag at the point of power disconnect where
lockout is required by each person
performing work. Each person shall be
provided with their own padlock and have
possession of the only key. If more than one
person is working on a machine each person
shall affix personal lock and tag using a
multi-lock device.
7. Tagout devices shall be used only when
power sources are not capable of being
locked out by use of padlocks and lockout
hasp devices. The name of the person
affixing tag to power source must be on tag
along with date tag was placed on power
source.
8. Release stored energy and bring the
equipment to a “zero mechanical state”.
9. Verify Isolation: Before work is started, test
equipment to ensure power is disconnected.
B. General Security
1. The lock shall be removed by the
“Authorized” person who put the lock on the
energy-isolating device. No one other than
the person/persons placing padlocks and
lockout hasps on power shall remove
padlock and lockout hasps and restore
power. However, when the authorized
person who applied the lock is unavailable to
remove it his/her Supervisor may remove
padlock/padlocks and lockout hasps and
restore power only if it is first:
a. verified that no person will be exposed to
danger.
b. verified that the “Authorized” person who
applied the device is not in the facility.
c. noted that all reasonable efforts to con-
tact the “Authorized” person have been
made to inform him or her that the lock-
out or tagout device has been removed.
d. ensured that the “Authorized” person is
notified of lock removal before returning
to work.
2. Tagout System—Tags are warning devices
affixed at points of power disconnect and are
not to be removed by anyone other that the
person placing tag on power lockout. Tags
shall never be by-passed, ignored, or
otherwise defeated
1.13 CALIFORNIA
PROPOSITION 65
WARNING
CALIFORNIA PROPOSITION 65 WARNING
Diesel engine exhaust and some of its con-
stituents are known to the State of Califor-
nia to cause cancer, birth defects and other
reproductive harm.
Battery posts, terminals and related acces-
sories contain lead and other compounds
known to the State of California to cause
cancer and birth defects and other repro-
ductive harm. Wash hands after handling.
15
 SECTION 1

1.14 SYMBOLS AND REFERENCES

The symbols below may or may not be used. Please
refer to the decals set forth on the machine for
applicable symbols.

DIESEL FUEL HEARING PROTECTION

ROTARY COMPRESSOR

HARD HAT
TEST RUN

DRAIN SAFETY GLASSES

HIGH PRESSURE
HEARING PROTECTION
SHUT-OFF VALVE
W/ SAFETY
DO NOT REMOVE
NO
MANUAL

ENGINE DO NOT BREATHE

COMPRESSED AIR
COMPRESSOR
DO NOT STAND ON
SERV. VALVE
ENGINE OIL
DO NOT OPERATE
ENGINE COOLANT W/ DOORS OPEN

WATER
DO NOT OPEN

OIL
DO NOT STACK

DO NOT ELECTRICAL SHOCK

CLOSED MECHANICAL
AIR FLOW

FUSE
HOT SURFACE
LOW PRESSURE
PRESSURIZED VESSEL
READ MANUAL
PRESSURIZED
COMPONENT
BRAKES SAFETY SYMBOLS 1

16
SECTION 1

DANGEROUS OUTLET ENGINE START

ENGINE ECM
REMOTELY
CONTROLLED
READ/WRITE DATA

CORROSIVE
INTAKE AIR

EXHAUST GAS
WARNING

FAN GUARD
DO NOT
MAINTENANCE

BELOW TEMPERATURE BELT GUARD

DO NOT TOW SERVICE POINT

BAR/PSI
LOW TEMPERATURE
BATTERY

BATTERY DISCONNECT STD AIR

OFF A/C AIR

ON
24 HOURS

RESET
BELTS

NO FORKLIFT FILTER

STRAINER
FORK LIFT HERE
SAFETY SYMBOLS 2

DIRECTION OF ROTATION

17
 SECTION 1

RADIATOR HOUR METER

AIR-CIRCULATING COMPRESSOR AIR

FAN PRESSURE

AIR-COOLED START
OIL COOLER
CONTROL
LIQUID-COOLED
OIL COOLER
ENGINE PREHEAT
LOW TEMP AID
LUBRICATION

ENGINE WARNING
TRAILER TOWING
MODE
FUEL LEVEL
AXEL
ENGINE RPM
LUBRICANT GREASE

ENGINE OIL
EXAMINE, CHECK PRESSURE

ENGINE COOLANT
CRUSH/PINCH POINT TEMPERATURE

COMPRESSOR
FUNCTIONAL ARROW TEMPERATURE

DO NOT MIX
ENGINE INTAKE COOLANTS
AIR FILTER

AFTERCOOLER
PRESSURE CONTROL BYPASS VALVE

INLET VALVE SPRING

DRAIN HEATER

INTERNAL FUEL
BATTERY HEATER

COMPRESSOR
EXTERNAL FUEL
OIL HEAT

STACKING LIMIT
SIDE DOOR T-LATCH BY NUMBER
SAFETY SYMBOLS 3

18
SECTION 1

DO NOT OPERATE WATER DRAIN

WHILE STACKED

PRESSURIZED SPRING SEVER (FAN)

DO NOT MIX FLUIDS

DEF FLUID ONLY

AUTO START/STOP
RUN

SAFETY SYMBOLS 4

FLUID DRAIN
Safety Symbols-3

19
 BLANK PAGE

20

Section 2
STARTUP PROCEDURES
2.1 INTRODUCTION
This compressor is equipped with a Sullair Compass
Controller for controlling the compressor system
operation, adjusting the machine parameters and
performing maintenance operations. The Compass
Controller utilizes digital technology that ensures
accurate and safe operation of the compressor
system. When fault conditions occur, the controller
automatically shuts down the machine to prevent
injury to the operator or damage to the equipment.
Features of the Compass Controller include:
• Dual gauges for display of pressure,
engine temp, compressor temp, engine
rpm, and fuel level
• LCD screen displaying machine status and
operating information
• Remote start capabilities
• Automatic self diagnosis at startup
• Multiple language support
• An external diagnostics port which allows
PC interface for configuration of the system
parameters.
• Backlighting of gauges with green LED to
allow clear view of gauges in low light
areas.
2.2 CONTROLLER PANEL
LAYOUT
The Compass Controller panel is shown in Figure 2-
1. The controller components and functions are
described in detail in Section 4.
2.3 COMPASS CONTROLLER
POWER UP
The compass controller is used to start the
compressor either manually or remotely.
Manual Start: Start the machine by pressing the
COMPASS CONTROLLER USER MANUAL
“OFF/ON/START” button to the “START” position on
the controller panel. Once the switch has been set to
the START position and the controller has
successfully initialized (see Self Test, Bus Checks,
Safety Checks this section for further information),
the Compass Controller will check status, then will
automatically continue to energize the starter until
either the engine starts or the maximum crank
duration is reached.
Auto Start: The compressor can be started
remotely if the remote start function has been
enabled during setup. If this option is activated, an
“ r. ” will display in reverse characters in the upper
right corner of the LCD display.
SELF TEST
When the controller is initially powered up, the
system will initiate a “Self Test” sequence to verify its
operational integrity and safety status. During this
process, the following self tests will be performed.
1. Gauge pointers will move to the zero posi-
tion, then to half and full scale, then back to
zero, and finally to the actual value reading.
2. The LCD display will turn on all its segments
for one second, off for one second, and then
display the Sullair logo followed by the soft-
ware product number with revision level.
3. All warning lights will turn on for 5 seconds
and then turn off, then set to the actual indi-
cator state.
The Self Test feature may be bypassed by disabling
the sequence as describe in Section 3 of this
manual.
COMMUNICATION BUS CHECKS
After successful completion of the self test, the
Compass Controller system will check the
communication status of system.
19
COMPASS CONTROLLER USER MANUAL SECTION 2

Figure 2-1: Compass Controller Panel

1 Mode Button (m) 12 Engine Warning Indicator

2 Trip/Reset Button (t) 13 Engine Diagnostic Shutdown Indicator
3 LCD Graphic Display 14 Engine Controller Diagnostic Service Port
4 Service Air Pressure Gauge (P1) 15 Engine Diagnostic Port Cover
5 Low Fuel Indicator 16 Compressor Shutdown Indicator
6 Fuel Level Gauge 17 Compressor Warning Indicator
7 High Compressor Temperature Warning 18 High/Low Selector Switch
8 Engine RPM Gauge 19 Reset Switch
9 Compressor Temperature Gauge 20 Power Off/On/Start Switch
10 High Engine Temperature Warning 21 Cabinet Latch
11 Engine Temperature Gauge

20
SECTION 2 COMPASS CONTROLLER USER MANUAL

In the event of a problem, the LCD will display one of Table 2-1 lists the safety conditions that are checked
the following messages: by the Compass Controller during startup and the
fault that will be displayed on the LCD screen if a
fault occurs.
Listening For Engine See Section 5 of this manual for troubleshooting
recommendations.
SYSTEM PRESSURE CHECKS
Following the successful completion of the general
safety checks, the Compass Controller will check the
status of the Service Pressure (P1), Control Pressure
(P2), and Wet Sump (P3). If there is a problem with
Checking Compass Comm any of these inputs a message will be displayed on
the LCD display indicating the nature of the problem.
(Example shown below):

Checking Pressures r.
The Compass Controller system will prevent the user P1 Signal Error
from operating the compressor until all
communication problems are resolved.
See Section 5 of this manual for troubleshooting
27.6 V Batt V
recommendations.
The controller will prevent compressor startup if
GENERAL SAFETY CONDITION CHECKS
either of the following conditions exists:
After successful completion of the Communication
• P1 pressure is greater than the maximum
Bus checks, the Compass Controlfler system will
P1 pressure permitted at startup. The
perform safety checks on the compressor and the
maximum P1 pressure is an adjustable
engine.
parameter which can be modified as
In the event of a problem with either the compressor describe in Section 3 of this manual.
or engine, a message will display in the LCD • P1 and P2 pressures are out of range.
indicating the nature of the trouble (example shown
below). The Controller will wait for user-interaction to See Section 5 of this manual for troubleshooting
either correct the fault or send the system to Sleep recommendations.
mode.

2.4 NORMAL OPERATION

Checking System r.
Following the successful completion of all startup
Low Fuel Level sequences, the system is ready for normal operation.
During normal operation the controller will be in one
27.6 V Batt V
of the following five operating modes: Ready, Start-
Up and Autostart (remote), Run, Sleep, and
Shutdown. Each of these modes is described in
detail in Section 4.

21
COMPASS CONTROLLER USER MANUAL SECTION 2

Table 2-1: Safety Conditions

User Controlled
Parameter Fault Condition LCD Message
Parameter

Fuel Low fuel level Very Low Level Alert Low fuel level
(% full)

Fuel sender open circuit None Low fuel level

Battery Low battery voltage None Battery Voltage Error

(<18.0Vdc)

Compresor Discharge Signal short circuit None T1 Signal Error

Temperature (CDT)
Compressor Temp High Max T1 during run or at Comp High Temp
start-up

Receiver Tank Temper- Receiver Tank Temp High None RTT High
ature (RTT)

Discharge Air DP High Aftercooler filter DP AfterFilters Equipped Primary Shutdown

Air Pressure (P1) Transducer signal short or None P1 Signal Error

open circuit

High compressor pressure Max P1 at start-p (psi) High Compressor Pres-

sure

Control Pressure (P2) Transducer signal short or None P2 Signal Error

open circuit

Air Pressure (P3) Transducer signal short or None P3 Signal Error

open circuit

22

Section 3
ADJUSTMENTS
3.1 INTRODUCTION
This section describes steps for using the Compass
Controller to modify specific parameters that control
the machine operation. Additional parameters can be
viewed and adjusted using the PC User Interface.
Part Number 02250173-104
MESSAGE DISPLAY CENTER
The message display is a graphical LCD that
displays information to the compressor operator.
The screen is backlit to allow the display characters
to be clearly visible under any lighting conditions. In
addition to basic operational information, a variety of
user- defined options may also be displayed when
specified. Fault messages are displayed whenever a
fault condition occurs. The LCD display also allows
the operator to view instrumentation diagnostic data
to aid in controlling the system operation and in
troubleshooting problems.
LINE 2 DISPLAY SELECTION
Pressing the “m” button for less than five (<5)
seconds allows the selection of the parameter to be
COMPASS CONTROLLER USER MANUAL
displayed on the second line. The parameter will
highlight in reverse characters indicating it is
selected. Press the “m” or “t” button to scroll the
display through the various parameters that are
available for user adjustment.
3.2 SETTINGS AND
DIAGNOSTIC
DIAGNOSTIC MENU
Once the initialization sequence is complete, the
operator can enter the diagnostic menu at any time
by pressing and holding the “m” button for more than
five seconds. If the operator enters the diagnostic
menu prior to getting past the Ready state, the
compressor will not be permitted to start until the
diagnostic menu is exited. When the Compass
Controller is in Ready mode, pressing the “m” button
for more than five (>5) seconds brings up the
following screen:
1-Set Units
2-Set Language
3-Contrast
Select
Pressing both the “m” and “t” buttons simultaneously
will make the highlighted parameter active for editing.
Pressing the “m” or “t” button separately will move
the highlight through the parameter list allowing other
items to be selected.
MENU STRUCTURE
The diagnostic menu will appear in the LCD display
as shown below. Use the “m” and “t” buttons to
scroll through the available menu selections. The
present menu item will display in reverse
characters. There are nine diagnostic menu
selections which can be chosen from this menu:
1. Set Units
23
COMPASS CONTROLLER USER MANUAL SECTION 3

2. Set Language
3. Contrast
4. COMPASS Diagnostics* (real-time data only) Language Changed
5. Pressure Calibration
6. Auxiliary Temperature Calibration
7. Backlight Adjust
8. Engine Diagnostics* (real-time data only)
9. Engine Shutdown History
1-English
To select a present menu item, press both the “m”
and “t” buttons at the same time. The operator can 2-French
then use the “m” and “t” buttons to modify the 3-Spanish
selected parameter.
Select
SET UNITS
When “Set Units” is selected, the LCD display will 4-German
show the following:
5-Italian
Current Units 6-Portuguese
ENGLISH Select
Press t for METRIC
A confirmation screen will appear indicating
Press m to exit “Language changed” before exiting back to
Diagnostic menu.

The operator can choose between English and CONTRAST

Metric units by pressing the “t” button. To make the
Selecting the Contrast option allows the operator to
units active, press the “m” button or simply let the
adjust the contrast of the LCD display. Press the
screen time out (approx. five seconds).
“m”(+) button to increase contrast. Press the “t”(-)
button to decrease contrast.

SET LANGUAGE
When “Set Language” is selected, the LCD display
will present six international languages for the
system display. The operator can scroll between the
available languages by pressing the “m” or “t”
CONTRAST ADJUST
buttons. The selected option will appear in reverse + -
characters. To make the selected language active,
press both the “m” and “t” buttons at the same time.

24
SECTION 3 COMPASS CONTROLLER USER MANUAL

THE COMPASS CONTROLLER DIAGNOSTICS GAUGE TEST

The Compass Controller Diagnostics menu contains
five tests that verify the functionality of specific
controller components. The Diagnostics menu can
only be entered if the compressor is in the Ready
mode (Prior to start-up).
Selecting this menu option will present a sub-menu
as shown below. To make a selection in the sub
menu, scroll to the desired option and press both the
“m” and “t” buttons at the same time. The diagnostic
menu exits after a short time-delay of inactivity.
The Gauge Test verifies that both gauges are
functional. During the test, the gauge pointers will
cycle from 0 to full scale pausing at 0%, 50%, 100%,
then return to zero (or its true position). The LCD
display will show which gauge is being tested and
indicate the gauge’s corresponding position (as
depicted below for engine speed). Pressing the “m”
button at anytime during the test will cause the test to
end.

1-Gauge Test
1-Gauge Test 2-Lamp Test
3-LCD Test
2-Lamp Test Select
3-LCD Test
Select

4-Binary Inputs Engine Speed

5-Analog Inputs Test 0%
EXIT
Select
Engine Speed
50%
NOTE EXIT

This sub-menu and all content accessible

from it will always be in English, regardless of
the language chosen.
Engine Speed
100%
As previously noted, the system must be in Ready EXIT
mode prior to entering the Diagnostics menu. An
attempt to enter the diagnostics while the machine is
running will cause the following message to be
displayed:

Not permitted
while running

25
COMPASS CONTROLLER USER MANUAL SECTION 3

LAMP TEST LCD TEST

Selecting the Lamp Test option will turn on all Selecting the LCD Test option will test all the pixels in
warning and binary LED’s (except for Engine Crank the LCD display by flashing the Sullair logo in normal
Relay). Each output will turn on, then off and the and reverse characters. Pressing the “m” button will
LCD display will indicate which output is being tested end the test.
(as depicted below for R/S Relay). Pressing the “m”
button at any time will end the test and return to the
COMPASS Diagnostic menu. The outputs tested 1-Gauge Test
during the lamp test are: 2-Lamp Test
1. Recirculation Solenoid Output
3-LCD Test
Select
2. Hi / Low Pressure Relay Output
3. Run / Start Relay Output
4. Compressor Warning Lamp
5. Compressor Shutdown Lamp
6. Engine Warning Lamp
7. Engine Diagnostics Lamp

1-Gauge Test
2-Lamp Test
3-LCD Test
Select

R/S Relay

EXIT ON

R/S Relay

EXIT OFF

26
SECTION 3 COMPASS CONTROLLER USER MANUAL

BINARY INPUTS
Selecting the Binary Inputs menu option will allow the S-1 Dp-Pry Wrn High
operator to check the status of each of the binary
S-2 Dp-Pry Shtdn Low
inputs to the Compass Controller. The Binary Inputs
display, as shown, will indicate the module being S-3 UNUSED 1 High
checked, the pin number of the connector for the S-4 UNUSED 2 Low
input, and real-time status of each binary input
defined in the system. The “High” and “Low” S-5 Hi/Low Press Low
designation refers to the voltage level at the
connector pin. S-6 Engine Wrn High
S-7 T3 - RTT Low
Press “t” to scroll through and view the status of the
various binary inputs. Press “m” to exit the module
S-8 Engine Diag High
and return to the COMPASS Diagnostic menu. The
15 Binary Input items available from this menu are M-11 Ign ON High
listed to the right. Note that the “S” designation is for M-12 Engine Start Low
the slave warning bank input and the “M” designation
is for master gauge input. M-13 Remote Start High
M-14 DP1-EIAF Low

M-15 E-Stop High

M-16 DP2-CIAF Low

Pin # Input Status of input

Module

4-Binary Inputs S-1 DP-Prv Wrn High

5-Analog Inputs S-2 DP-APF Shtd Low
S-3 Unused 1 High
Select S -4 Unused 2 Low

27
COMPASS CONTROLLER USER MANUAL SECTION 3

ANALOG INPUTS
Selecting the Analog Inputs screen allows the
operator to check the status of each of the analog
inputs coming to the Compass Controller system.
This LCD screen displays the master gauge pin
number and real-time status of each analog input
defined in the system.
Press “t” to scroll through and view the status of the
various analog inputs. Press “m” to exit the module
and return to the COMPASS Diagnostic menu. The
eight analog input items available from this menu are
listed below. Note that the “M” designation in the
module number indicates “master” gauge input.

M-1 Fuel 55%

M-2 P1 Serv p 0 psi
M-3 P2 Ctrl p 0 psi
M-4 P3 Wet p 0 psi

M-5 Vdc Ref 5.00V

M-6 T1 CompT 198 °F
M-7 FaultReset Off
M-8 T2 Aux T 109 °F

Pin #

Module Input
Value

4-Binary Inputs
M-1 Fuel 100%
5-Analog Inputs
M-2 P1 Serv P. 0 psi
M-3 P2 Ctrl P. 0 psi
Select
M-4 P3 Wet P. 0 psi

28
SECTION 3 COMPASS CONTROLLER USER MANUAL

PRESSURE CALIBRATION AUXILIARY TEMPERATURE CALIBRATION

Over time the P1, P2, and P3 pressure transducer Occasionally, and when the auxiliary temperature
values might drift resulting in an inaccurate reading input is first configured, the input may require
showing on the pressure gauge. Using the Pressure calibration to adjust the input to the actual known
Calibration function the operator can adjust the temperature. This is accomplished using the
actual zero pressure to 0.00 BAR when no pressure Auxiliary Temperature Calibration function. The
is present in the compressor. The offset value will be auxiliary temperature calibration offset is
subtracted from the transducer value to obtain an configurable in 0.5°C increments. A total offset of +/-
adjusted reading used for indication and calculation. 10°C is allowable. The offset will be applied to the
RTD input signal and used for indication and
To calibrate a pressure transducer:
calculation during compressor operation.
1. Select the transducer (P1, P2, or P3) to be
To calibrate the Auxiliary Temperature input:
calibrated by pressing both the “m” and “t”
buttons at the same time. 1. Select the Aux Temp input by simultaneously
pressing both the “m” and “t” buttons when
2. The following screen sequence will be pre-
the input is highlighted.
sented (example below). This example
shows a P1 pressure of .60 BAR on a 2. The following screen will be presented
machine that is known to actually be at zero (example).
pressure. The current pressure value is dis-
3. Adjust the offset value using the m and t but-
played in metric units only (1 kPa = 0.01
tons.
bar).
4. Simultaneously press m and t to exit screen.
3. Calibrate the actual pressure reading back
down to 0.00 by increasing the value of the
correction / offset by pressing the “t” button
until the Actual Pressure reads 0.00. Once
this is done, simply press both the “m” and + Aux Temp Cal -
“t” buttons together to store this value in the
system. The offset value will be subtracted
42.5°C
from the transducer value to obtain the
adjusted reading. The calibration offset is
configurable in steps of -50 to +50 with 0 the
factory default. Each step is approximately
equal to ±1 kPa (±0.15 psi) on machines
less than 300 psi and ±3.25 kPa (±0.47 psi)
on machines over 300 psi.

1-P1 (Service)
2-P2 (Control) + P1 Calibration -
3-P3 (Wet)
Select 0.60 BAR 0

Actual Pressure Correction /

being sent from Offset
the transducer

29
COMPASS CONTROLLER USER MANUAL SECTION 3

BACKLIGHT ADJUST ENGINE SHUTDOWN HISTORY

With this function the operator can adjust the
intensity of the gauge backlighting (both the master
gauge, and the 4-in-1 gauge) from 0% (off) to 100%
(full intensity). The factory default is 20%.
To adjust the backlight intensity:
1. Press the “m” button to increase the light
intensity.
2. Press the “t” button to decrease the light
intensity.
3. Simultaneously press “m” and “t” to exit the
screen.
This function allows up to 5 of the most recent
abnormal shutdown faults to be viewed. The Engine
Shutdown History is an instantaneous snapshot of
the Compass Controller parameters. For each fault,
the LCD will display the fault that occurred and the
engine hours at the time of the fault. Use the “m” and
“t” buttons to scroll thru each of the faults. Press “m”
and “t” to exit. Pressing the Compass Reset button
will cycle through the warnings active at time of
shutdown. An example of a “High Compressor
Temp” shutdown with 150 hours on the engine is
shown below.

Comp High Temp

150.00 hrs
BACK LIGHT ADJUST exit
+ -

3.3 CONFIGURATION MENU

ENGINE DIAGNOSTICS
The Engine Diagnostic screen is a real-time display
of active operation messages being transmitted by
the engine. Messages that become inactive are
automatically erased. No messages are stored in the
controller memory.
When this function is selected, up to 5 of the most
recent active engine Fault Mode Indicators (FMI) or
Suspect Parameter Number (SPN) codes being
received from the Caterpillar engine will be
displayed. Use the “m” and “t” buttons to scroll
through the various codes. Simultaneously press
“m” and “t” to exit.
No Active Codes
exit
OR
The Compass configuration menu allows for end-
user adjustment of five User Controlled Parameters
(UCP). The UCPs do not adversely affect the
controller’s operational functionality. The
configuration menu allows for end-user
customization of the Compass Controller. The
configuration menu will compile and store to the
controller memory any changes to the factory
programmed UCP profile.
To enter the Configuration Menu:
1. Hold down the “m” and “t” buttons while
cycling Compass Controller power to ON.
The configuration menu will appear.
2. Use the “m” and “t” buttons to navigate
within the menu and to make adjustments to
the selected parameters.
3. Exit the Configuration Menu by simultane-
ously pressing “m” and “t” buttons. After exit-
ing, the master gauge will perform a system
reset and then enter Start-up mode.

SPN 100 FMI 1

SPN 110 FMI 0
End of list
exit

30
SECTION 3 COMPASS CONTROLLER USER MANUAL

LINE 2 PARAMETER DISPLAY REMOTE START

The Line 2 parameter display typically shows the
operational parameters of the Compass Controller.
Disabling this feature will only affect the parameter
display. Priority messages will still utilize the lower
portion of the LCD to display messages as
necessary. Select “yes” to enable the parameter
display or “no” to disable the display.
Line 2 Parameter?
yes no
The ability of the Compass Controller to recognize a
remote start actuation can be enabled or disabled
using the configuration menu.
NOTE
A hardware remote start signal must be
provided in addition to enabling the soft-
ware feature. Select “yes” to activate the
remote start feature or “no” to disable the
feature.

Ok Exit Toggle
Enable Remote Start?
SELF TEST yes no
The Self-Test function of the Start-up mode can be
enabled or disabled using the configuration menu. Ok Exit Toggle
Select “yes” to enable or “no” to disable the Self-Test
feature.

Self Test?
yes no

Ok Exit Toggle

WARNING
DO NOT adjust this parameter unless spe-
cifically instructed to do so by the factory.
Changing this setting will cause the
machine to run improperly.

31
COMPASS CONTROLLER USER MANUAL SECTION 3

3.4 USER ADJUSTABLE CONTROL PARAMETERS (UCP)

The following settings are configurable using the parameters listed in bold font are those which can
Compass Controller interface software. The cause abnormal shutdowns to occur.

Engine Crank Default Value Range/Option

Crank On Duration (sec) 10 3-10
Crank Off Duration (sec) 10 4-30
Number of Cycles 3 1-5
Engine Cranked Speed (RPM) 250 200-500
Time Required At Cranked Speed (msec) 480 240-1000

Throttle Control Default Value Range/Option

Low pressure Max Duty Cycle (%) 92 70-92
High Pressure Max Duty Cycle (%) 92 70-92
LO Idle Engine Speed (RPM) 1400 1300-2000
HI Idle Engine Speed (RPM) 1800 1500-2100
Alt Throttle Control 100-120 100-120
Low Pressure Range – 300 PSI controller 125-145
Alt Throttle Control 150-170 150-170
High Pressure Range – 300 PSI controller 175-195
200-220
Alt Throttle Control 205-225 205-225
Low Pressure Range – 600 PSI controller 350-370
Alt Throttle Control 350-370 350-370
High Pressure Range – 600 PSI controller 425-445
500-520
Low Speed Shutdown Settings Disabled Enabled
Disabled
Low Speed Shutdown RPM 800 800
900
1000
1000
Low Speed Shutdown Time (sec) 5 5
7
9
11

32
SECTION 3 COMPASS CONTROLLER USER MANUAL

Fuel Level Default Value Range/Option

Cancel Low Level Alert (% full) 23 13-43
Low Level Alert (% full) 20 10-40
Cancel Very Low Level Alert (% full) 11 7-13
Very Low Level Alert (% full) 8 4-10

Temperature Settings Default Value Range/Option

Max CDT at run-time or startup (°F) 250 200-400
Max Aux Temp at run-time/startup (°F) 250 200-400
Engine Temp. for warm-up complete (°F) 70 64-150
AfterFilter Freeze Assert Temp. (°F) 39 (-40) -50
AfterFilter Freeze Cancel Temp. (°F) 45 (-40) -68
Startup Aids Settings - -
Low Point Temp (°F) (-40) (-40) -16
Low Point Time (min) 60 31-75
Middle Point Temp (°F) (-15) (-15) -9
Middle Point Time (min) 30 16-30
High Point Temp (°F) 10 10-20
High Point Time (min) 15 5-15

Pressure Settings Default Value Range/Option

Max P1 at run-time (PSI) 200 145-600
Max P3 at run-time (PSI) 200 145-600
Allowable time for Max P1 or P3 (sec) 1 1
5
15
30
Max Air-Oil-Sep at run-time (PSI) 15 10-20
Air-Oil-Sep alert time (sec) 15 10-60
Max P1 at startup (PSI) 10 0-15
Manifold Solenoid Open/Assert Pressure (PSI) 60 30-90
Manifold Solenoid Close/Cancel Pressure (PSI) 55 25-85
P1 Calibration Offset 0 -50 to +50
P2 Calibration Offset 0 -50 to +50
P3 Calibration Offset 0 -50 to +50
P1 to shutdown from auto-start (PSI) 100 70-600
Required time for P1 > Above Value to shutdown 900 300-1800
from auto-start (sec)
P1,2,3 Pressure for Cooldown Completion (PSI) 10 5-15
P2 Pressure for max RPM at run-time (PSI) 5 0-10

33
COMPASS CONTROLLER USER MANUAL SECTION 3

System ID Default Value Range/Option

ID Tag N/A 20 character user
entry

Miscellaneous Settings Default Value Range/Option

Warmup Complete Speed (RPM) 1375 1375-1450
Minimum Engine Warm-up Time (sec) 30 5-60
Maximum Engine Warm-up Time (sec) 240 60-360
Compressor Cool-down Time (sec) 300 5-600
DP1-2 Alert Time (sec) 15 10-60
LANGUAGE English English
Spanish
Italian
French
German
Portuguese
ECM Power-Off Interval At Cooldown (sec) 5 3-10
Unit Of Measurement English Metric
English
PSI System 600 300-600
Fuel Tank Large 02250154-804
02250141-157
02250160-656
02250190-811
No Tank
Display 2nd Line Parameter Enabled Enabled
Disabled
Enable Gauge Self-Test Enabled Enabled
Disabled
Remote Start Permitted Disabled Enabled
Disabled
C9 Engine Used Disabled Enabled
Disabled
AfterFilters Equipped Disabled Enabled
Disabled
Intake Louvers Equipped Disabled Enabled
Disabled
Enable Inactivity Auto-Sleep? Enabled Enabled
Disabled
Inactivity Timeout (min) 10 5-20

34

Section 4
DESCRIPTION
4.1 INTRODUCTION
This section describes the operation of the Compass
Controller, the function of the controller components,
and the various types of displays that may appear on
the display screen. Descriptive lists of all messages
appearing in the display are also provided.
4.2 OPERATING MODES
SLEEP MODE
Sleep mode occurs when the Compass Controller is
not powered on. All electrical components are
inactive during Sleep mode to prevent battery
drainage (i.e. microprocessor, relays, indication
lamps, etc).
Sleep mode is dependent upon the position of the
Off/On/Start switch and current operating status of
the compressor. If the compressor is in any state
other than running, then placing the Off/On/Start
switch in the OFF position will enter Sleep mode. If
the compressor is running, placing the Off/On/Start
switch in the OFF position will initiate Cooldown
mode followed by Sleep mode.
If the compressor has shutdown due to fault
condition, then the fault must be acknowledged by
pressing the reset switch and switching the Off/On/
Start switch to the OFF position.
If the compressor was enabled via Remote Start, a
compressor malfunction will allow entering Ready
mode only. The malfunction must be acknowledged
by pressing the Reset switch and Off/On/Start switch
must be in the OFF position to enter into Sleep
mode.
COMPASS CONTROLLER USER MANUAL
START-UP MODE
Start-up mode initializes the system instrumentation
components for operation. Start-up mode is internal
to the Compass Controller and does not permit
engine/compressor activation.
Start-up mode is enabled by one of the following
two methods:
1. Press the Off/On/Start switch to ON.
2. Activating the Remote Start switch (if
enabled).
Placing the Off/On/Start switch to the ON position will
energize the Master Gauge and begin initializing the
system for Ready mode.
If Start-up is entered by placing the Off/On/Start
switch in the ON position, placing the switch in the
OFF position powers down the entire system. If a
start-up initialization parameter is out-of-tolerance,
the Compass Controller will enter a safe-shutdown
state and demand user interaction to completely
power down the unit.
NOTE
If the Start-up mode is entered via Remote
Start, then only a start-up initialization
parameter “out-of-tolerance” failure and
“Remote Start binary input not low” will
exit Start-up mode and prevent entering
Waiting mode. Otherwise, the Compass
Controller will maintain Start-up mode sta-
tus while waiting for allowable conditions
to begin initializing Waiting mode.
It is during Start-up mode that system integrity is
verified. System integrity verification involves checks
of functional instrumentation, communication status,
and confirmation of proper initial parameter settings.
A successful completion of Start-up mode transitions
the Compass Controller to the Ready mode.
35
COMPASS CONTROLLER USER MANUAL
READY MODE
When the controller is in Ready mode the LCD
display will indicate that the system is ready to be
started, as shown below.
Ready . . .
ok (P3-P1)
The compressor can be started in one of the two
ways as described in Section 2. When the
compressor is waiting to be started remotely, an “ r. ”
in the upper right corner of the LCD will display in
reverse characters as shown below.
Ready . . . r.
198°F Comp Temp
NOTE
For remote start applications, an appro-
priate trickle charge must be applied to
the batteries in order for the compressor
to maintain Start-up readiness.
If configured for remote start, the inactiv-
ity auto sleep UCP is disregarded and no
auto-sleep transitions will occure.
When the appropriate remote start conditions are
met, the system will automatically enter the Start-up
mode, and the compressor will start.
While the compressor is attempting to start in both
Manual and Remote start mode, the LCD will display
the following:
36
SECTION 4
Engine Cranking r.
0 PSI Serv Pres…
Ok Exit Toggle
Ready mode is a transitional state between
initialization of the Compass Controller, operation of
the compressor and compressor shutdown. In
Ready mode, the Compass Controller is ready to
enter an operational state. However, the compressor
is not active in Ready mode. Ready mode is
characterized by “Ready… ” appearing on the LCD
1st line parameter display. If Remote Start is
configured then “Ready… r. ” will be displayed.
Ready . . . r.
198°F Comp Temp
Ready . . . r.
Starting Aids Required
198°F Comp Temp
Ready mode to Run mode is dependent on user
initiation of a compressor start enabler.
• Manual Start – initiated by the Start/On
switch placed in the Start position.
• Auto (Remote) Start or Remote Start
Momentary – Remote Start enabled.
In Ready mode, the Compass Controller is analyzing
specific system parameters to determine if entering
Sleep mode is allowable. When the necessary
conditions are met, the system enters Sleep mode
and all electrical components are de-energized. If
the compressor was enabled via Remote Start, the
Start/On/Off switch is disabled and only a
compressor malfunction will allow entering Ready
SECTION 4 COMPASS CONTROLLER USER MANUAL

mode and then Sleep mode.
FAILURE TO START
In manual mode, if the engine does not start, the
Compass Controller will attempt another start cycle
as long as the maximum number of crank attempts is
not exceeded. This is an automatic process until the
Start attempts equal the set maximum.
In Run mode, the compressor is ready to supply
service air. The engine RPM will automatically be
adjusted to maintain the desired air pressure. If the
2nd line parameter (UCP) has been turned on, the
operator can scroll thru the list of available
parameters by momentarily pressing the “m” button.
Each press of <5 seconds will scroll one parameter.
The available parameters are listed below.

If the maximum number of crank cycle attempts (a Engine Speed

preset value) is exceeded, the system will display an Engine Hours (Hourglass symbol)
error message in the LCD display as shown below,
and the system will wait until the “Reset” switch is P1 Service Pressure
pressed. Once the “Reset” switch is pressed, the P2 Control Pressure
Compass Controller system will shut down. Restart
the compressor by switching the Start/On switch to P3 Wet Pressure
ON. (P3-P1) Air-Oil Separator Pressure
Compressor Tank Temperature
Ambient –or- Service Temperature

Engine Over Crank Engine Coolant Temp

Battery Voltage
Press Reset to Clear % Engine Load
Fuel Rate
When Remote is enabled, if the engine does not
start, the “Fault / Reset” switch will need to be Fuel Pressure
depressed to reset and shut the machine down. The
Fuel Temperature
system will then wait for the appropriate start-up
conditions and then activate the remote start input to Engine Inlet Air Temperature
start the compressor.
Oil Pressure
RUN MODE Boost Pressure
Once the compressor has completed the warm up Desired Engine Speed
cycle, it will phase into Run mode. When in Run
mode, the LCD display will look similar to the display Aux 1 Pressure
shown below. Aux 1 Temperature

Remote Start
System Service enabled icon
Pressure 110 PSI r.

0 PSI Serv Pres …

Scrollable
2 nd line

37
COMPASS CONTROLLER USER MANUAL
AUTO-START (REMOTE) CONFIGURATION
When using the Auto-Start feature, there are two
parameters that can be set by using the Compass
Controller Communicator Software tool on a laptop
computer. The first is the P1 System Service Pres-
sure, and the second is the time duration that the
compressor must stay at or above the P1 pressure.
These values are settable when the Compass Com-
municator software and communication adapter are
installed. When the compressor is operating in Auto-
Start Mode, it will not enter a normal Shutdown
mode until both conditions below are met.
a. The System Service Pressure (P1) is greater
than the UCP (User Configurable Parame-
ter) specified level for the UCP specified
duration.
b. The “Remote Start” input has returned to its
normally open position.
In the event that an abnormal shutdown occurs, the
compressor could shut down without these
conditions being met. See Section 5:
TroubleShooting for handling abnormal shutdowns.
SHUT DOWN
The Shutdown mode can be entered when either of
the following conditions occurs:
If the Compass Controller system was started manu-
ally, the operator must press the “Off/On/Start”
switch to the OFF position.
If the Compass Controller system was auto-started
(Remote), the system will enter Shutdown mode
when both the Service Pressure (P1) is greater than
the specified level for the user-specified duration
(Note: Both of these values are pre-set), and when
the remote start binary input is deactivated.
When the system enters the Shutdown mode, the
compressor will complete the following tasks before
shutting down:
1. The LCD will display the message shown
below.
Stop Initiated
Cool Down Cycle
1400 rpm eng speed
38
SECTION 4
2. The engine will go to the low idle setting
(1400 RPM) for a preset period of time.
3. When the cool-down cycle is complete, the
engine will shut down.
4. The Compass Controller will continue to
monitor P1, P2, and P3 inputs until they fall
below the specified level (Note: This value is
pre-set), and the LCD will display a message
similar to the one shown below.
Monitoring Pressures
0 PSI Serv Pres …
This is displayed as a safety measure that
indicates to the user that the system is under
pressure.
5. When the system pressures fall below the
pre-determined levels, the controller will
enter Sleep mode.
NOTE
If while the engine is cooling down during
the normal shutdown phase, but is still
running, the operator presses the "Off /
On / Start" switch back to the momentary
"Start" position (or if the Remote Start
input becomes active and the Compass
Controller is configured to accept Remote
Start), the system will immediately re-
enter the Warm Up phase of the Start-up
mode.
However, during the final portion of shutdown, after
the Compass Controller has stopped the
compressor’s engine, the Compass Controller no
longer pays attention to the "Off / On / Start" switch
(or Remote Start). The operator must wait until this
phase completes to restart the compressor.
SECTION 4
GAUGES DISPLAY
Master Gauge –Service Air pressure
The air pressure gauge is driven by the air pressure
sender analog input. Open and shorts of the P1
Pressure sender analog input are considered out of
range and will force the pointer to fluctuate full scale.
4-in-1 Gauge
The 4-in-1 slave gauge displays Engine Coolant
Temperature, Engine Speed Compressor
Temperature and Fuel Level. Compressor
Temperature and Fuel Level are driven by analog
inputs. Open and shorts of the fuel level sender
analog input are considered out of range and will
force the pointer to fluctuate full scale.
MESSAGE DISPLAY CENTER
The message display consists of a graphical, backlit,
LCD display on the master gauge. Two input buttons
located directly below the LCD, the “m” (mode) and
“t” (task) buttons, allow user to navigate through the
LCD display.
As the Compass Controller system is executing in
any of its states, the LCD displays information to the
user that is pertinent to its operation and the
compressor state. In addition, through navigation
with the “m” and “t” buttons, menus may be solicited
to alter system behavior, modify the information
displayed, and make selection of the display
parameters.
PRIORITY MESSAGES
Priority messages are displayed in the LCD due to
various inputs or data messages. The priority
message will take over the second line (parameter
line) of the screen. Multiple messages may be
displayed by continually showing the message for 2
seconds before displaying the next message. Some
messages can be acknowledged by pressing the “m”
button while the message is being displayed. Once
acknowledged, the priority message will leave the
display. Certain acknowledged priority messages
may redisplay if the condition still exists after three
minutes, others will not reoccur until the next key-on
cycle.
COMPASS CONTROLLER USER MANUAL
POWER-UP OPTIONS MENU
The menu is activated by pressing and holding down
both the “m” and “t” buttons while powering-on the
Compass Controller by pressing the “Off/On/Start”
button on the front panel. When performed, the
following “yes/no” options will appear. The current
setting (either yes or no) is displayed in reverse
characters.
Navigation of the menu is as follows:
• Press “m” to move circularly through the
options.
• Press “t” to toggle the yes / no setting of
the current option
• Press both “m” and “t” to exit the menu,
saving the current settings in the Compass
Controller’s non-volatile memory.
Momentary Start—(Only displayed when BOTH
Rem Start Momentary? AND Remote Start Enabled?
are set to Yes). The remote stop will operate as
outlined in the Auto-Start (Remote) Operation in
this section. Alternatively, if Momentary Start is set to
“No”, the remote start input will act in the same
manner as the Off/On/Start switch on the panel in
that if the circuit is closed the machine will start and if
the circuit is opened then the machine will go into
shutdown mode and ultimately power down.
NOTE
This configuration is typical of a manned
remote control room/station where a
machine(s) are manually started and
stopped as needed.
Momentary Start?
yes no
Ok Exit Toggle
m t
750psi P2 Transducer - When “Yes” is selected the
controller is using an algorithm with suitable scaling
39
COMPASS CONTROLLER USER MANUAL SECTION 4

to send proper engine speed commands to the CAT attempt to start the engine once in the Ready state.
ECM. When “No” is selected a 250spi (control)
transducer is used and the engine speed control Enable Remote Start?
algorithm is switched accordingly to maintain proper
engine speed.. yes no

750PSI P2? Ok Exit Toggle

yes no
Ok Exit Toggle
m t
Line 2 Parameter – enables the display of an
additional compressor / engine parameter during
Running state. The first line parameter during
Running state is always the system service pressure
(P1) The second line may display any of several
possible parameters.
m t
MAIN SCREEN WHILE NOT IN RUNNING STATE
Prior to transitioning into the Running state, the
Compass Controller displays messaging indicating
the operational state of the Compass Controller
system. For example, while in the System Pressure
Checking phase of the System Power-up, Check &
Initialize state, the Compass Controller will indicate
“Checking Pressures” on the LCD display. During the
Engine Cranking phase of the Starting state, the
Compass Controller displays “Cranking Engine”.

Line 2 Parameter? BACKLIGHTING

yes no Gauge backlighting is a user configurable parameter
specified using a menu entry. Lower and upper levels
of the UCP are 0% to 100% intensity. The specific
Ok Exit Toggle parameter value is stored in the Compass Controller
(EEprom) memory.

m t GAUGES INTERNAL WARNING INDICATORS

High Coolant Temperature
Self Test - determines whether the gauge self test is The High Coolant Temperature indicator light will
performed at start-up upon entry to the System turn on when the Compass Controller receives the
Power-up, Check & Initialize state. corresponding output signal from the Caterpillar
engine.
Self Test? Low Fuel Level
yes no The Low Fuel Level indicator light will turn on when
the fuel level is less than UCP “low fuel level assert”
value. It will turn off when the level is above the UCP
Ok Exit Toggle “low fuel level cancel” value.

m t High Compressor Temperature

Remote Start - determines whether the activation of
the normally open low-side remote start input can
The High Compressor Temperature indicator light
will turn on when the T1 compressor temperature is
greater than or equal to the UCP specified for
Maximum T1 Compressor Temperature.

40
SECTION 4
WARNING BANK INDICATORS
Engine Warning
The engine warning indicator is on when the engine
warning input is pulled to ground. The state of this
indicator lamp directly follows the engine warning
output signal from the Caterpillar engine.
Engine Diagnostic
The engine diagnostic indicator is on when the
engine diagnostic input is pulled to ground. The state
of this indicator lamp directly follows the engine
diagnostic output signal from the Caterpillar engine.
Compressor Warning
The compressor warning indicator lamp is turned on
when one or more of the following conditions exists:
1. Aux Temperature > Maximum Aux Temp. at
Run Time (UCP)
2. Aux Temperature out of range
3. DP1, 2, (3, 5 if equipped with After-coolers)
active for a UCP-specified time duration
4. P1, P2 or P3 pressure out of range
5. (P3-P1) > Max Permitted Air-Oil Pressure
(UCP)
6. Fuel Level Low
7. Fuel Sender out of range
8. T1 Compressor Temperature out of range
9. After-cooler Freeze-up Imminent or Louver
Closed conditions
4.3 COMPRESSOR SHUTDOWN
The compressor shutdown indicator lamp is turned
on when one or more of the following conditions
exists. In addition, the system is immediately
shutdown when the condition occurs.
1. T1 Compressor Temperature > Max.T1
Temp. At Run Time (UCP)
2. RTT switch input is active (Includes the Inter-
stage Temperature switch (IT) on XH and
XHH machines)
3. DP4, 6 (if equipped with After-coolers) active
for a UCP-specified time duration
4. Very Low Fuel Level
5. P1, P2, & P3 pressure signals out of range
simultaneously
COMPASS CONTROLLER USER MANUAL
6. P1 > Max. permitted P1 pressure at run-time
7. P3 > Max. permitted P3 pressure at run-time
NORMAL SHUTDOWNS
The Compass Controller enters the Shutting Down
state in preparation for a normal shutdown when
either of the following conditions is met:
1. When currently in the Starting or Running
state and the Compass Controller system
was started manually, the operator presses
the “Off/On/Start” switch to the OFF position.
2. When currently in the Running state and the
Compass Controller system was auto-
started, the system service pressure P1
exceeds the UCP specified level for a UCP
specified duration AND the Remote Start
input has been returned to its normally open
(disabled) position.
NOTE
If the operator switches the “On/Off/Start”
switch back to the momentary Start position
before the Compass Controller transitions to
the OFF state, the Compass Controller will
re-enter the Warm-up phase of the Starting
state.
NOTE
If the Remote Start is once again enabled
before the Compass Controller transitions to
the OFF state during the shutdown sequence
from an auto-start operation, the Compass
Controller will re-enter the Warm-up phase
of the Starting state.
ABNORMAL SHUTDOWN
An abnormal shutdown is defined as any shutdown
that occurs for any reason other than that discussed
in the Normal Shutdown section. Any of the following
conditions will cause the compressor to be shut
down:
1. Engine sends a “Stop Engine” command
over the data bus
41
COMPASS CONTROLLER USER MANUAL
2. Fuel level reached the “Very Low” level
3. P1 Air pressure exceeds P1 maximum value
allowed
4. P1, P2, & P3 pressure signals out of range
simultaneously
5. P3 Pressure exceeds P3 maximum value
allowed
6. T1 Compressor temperature exceeds T1
Maximum value allowed
7. RTT/IT/ input becomes activated
8. DP4 after-cooler is activated (if system uses
after-coolers)
9. DP6 after-cooler is activated (if system uses
after-coolers)
10. Loss of the Compass Controller internal data
bus
11. Engine crank cycle is exceeded
12. Engine crank cycle engine speed is unknown
(not reported to the Compass Controller by
engine)
13. Engine speed while in running phase is
unknown (not reported to the Compass
Controller by engine)
14. Emergency Stop is activated
15. Engine Speed too slow (if enabled)
16. Low discharge pressure (in 600PSI systems
if P3 is less than 70PSI for 30 sec. during
runtime)
NOTE
Those conditions listed in bold font above
are User-Configurable Parameters.
Any of the preceding conditions will cause the
compressor to stop immediately. The LCD display
will indicate what the cause of the shutdown is,
similar to the example shown below:
42
SECTION 4
Engine Over Crank
Press Reset to Clear
The Compass Controller system will prevent the
compressor from restarting until the operator
acknowledges the fault by pressing the “Reset”
switch.
ABNORMAL SHUTDOWN EVENTS
Abnormal shutdown information is stored and
retained across power-up sessions of the system in
the Compass Controller memory. The abnormal
shutdown event data can be retrieved, displayed and
analyzed using the Compass Communicator
Software program. Refer to Section 5 for steps to
troubleshooting abnormal shutdown events.
The following information is stored for each of the
five most recent abnormal shutdown events that
have occurred within the Compass Controller.
• Shutdown Fault Type
• Engine Hours at time of Fault
• P1, P2, P3 pressure at time of Fault
• T1, Aux Temp at time of Fault
• Fuel Level at time of Fault
• Vdc reference voltage at time of Fault
• Pending Warnings at time of Fault
• State of DP1-6 and RTT switch inputs time
of Fault
• Start Switch and Remote Start Switch
inputs at time of Fault
• High/Low pressure switch at time of Fault
• Lin bus and J1939 bus status at time of
Fault
• Engine Speed at time of Fault
• Battery Voltage at time of Fault
• Engine Boost Pressure at time of Fault
• Engine Inlet Manifold Temperature at time
of Fault
• Engine Coolant Temperature at time of
Fault
SECTION 4 COMPASS CONTROLLER USER MANUAL

• Engine Fuel Temperature at time of Fault

• Engine Oil Pressure at time of Fault
• Engine Fuel Pressure at time of Fault 110 PSI r.
• Engine Load at time of Fault
• Number of Active FMIs from Engine at time
of Fault
• First FMI/SPN data if active from Engine at
23 PSI Boost Pres

time of Fault
• Engine Lamp Status if any active FMIs from
Engine at time of Fault
NOTE
MAIN SCREEN WHILE IN RUNNING STATE The “r.” indication does not indicate that the
current Running state was entered via the
Once the Compass Controller transitions into the
Remote Start input, but only that remote start is
Running state, it continuously displays the system
enabled.
service pressure on the top half of the LCD display.
The bottom half of the screen will display associated
engine/compressor parameters. The parameter last Once in the Running state (Assuming the 2nd Line
displayed when the controller was shutdown will be Parameter is turned on), momentarily pressing the
the active display parameter at the next power-up “m” button (<5 seconds) will scroll the second line
session. through all available parameters. The list of available
An example display while in the Running state is parameters is as follows:
shown below. The presence of the “r.” in the upper
right hand corner of the display indicates that the
Compass Controller is remote start enabled.

Parameter Title Displayed on LCD Line 2 Parameter Description

Eng speed Engine Speed as reported by engine
Hour glass icon Cumulative Engine Operation Hours
Serv pres Current P1 service pressure measurement
Cntrl pres Current P2 control pressure measurement
Wet pres Current P3 control pressure measurement
Current P3 minus P1 (differential pressure of separator
(P3-P1) element)
Comp temp Compressor Tank temperature (T1 sensor)
Aux1 sensor temperature (displays as ambient if
Amb temp –or- Serv temp after-coolers not configured for system)
Coolant Temp Engine Coolant Temperature – J1939
Batt V Battery Voltage – J1939
Eng Load Engine Load % - J1939
Fuel Rate Fuel Consumption Rate – J1939
Fuel pres Fuel Pressure – J1939
Fuel temp Fuel Temperature – J1939
Eng Air Temp Engine Air Temperature – J1939
Oil Pres Engine Oil Pressure – J1939
Boost Pres Engine Boost Pressure – J1939
Des Speed Desired Engine Speed – J1939
Aux1 pres Engine Aux1 Sensor Pressure – J1939
Aux1 temp Engine Aux1 Sensor Temperature – J1939

43
NOTES

44

Section 5
TROUBLESHOOTING
5.1 TROUBLESHOOTING
INTRODUCTION
This Troubleshooting section is provided as a guide
to aid in diagnosing and resolving compressor
problems when they occur. The information
contained in Table 5A, Troubleshooting Guide, has
been compiled from factory experience and contains
symptoms and usual causes for the described
problems. Each warning or fault message is listed
with conditions of when the problem may occur, a
probable cause, and a suggested solution to the
problem. DO NOT assume that these are the only
problems that may occur. This document cannot
address every possible adverse condition that may
occur nor does it provide every solution for the
potential troubles listed. All available data
concerning the trouble should be systematically
analyzed before undertaking any repairs or
component replacement procedures.
Always perform a detailed visual inspection when a
machine problem occurs prior to attempting any
repairs. Doing so may avoid unnecessary repair
and/or additional damage to the compressor.
Always remember to:
a. Check for loose wiring, loss of ground, wire
termination, etc.
b. Check for damaged piping.
c. Check for parts damaged by heat or an elec-
trical short circuit, usually apparent by discol-
oration or a burnt odor.
Should your problem persist after making the
recommended check, consult your nearest Sullair
Distributor or the Sullair factory Service Department.
COMPASS CONTROLLER USER MANUAL
NOTE
Section 5.3 portrays common systematic
problems that can occur during controller
operation. For a more thoroughly in-depth
coverage of the compressor operation trou-
bles, consult the Troubleshooting Section in
the machine’s operator’s manual.
5.2 TROUBLESHOOTING GUIDE
INTRODUCTION
The following guide contains symptoms and usual
causes for the problems that may occur throughout
the compressor system. Each warning or fault
message that may appear is listed along with
conditions for the problem, a probable cause, and a
suggested solution to the problem. DO NOT assume
that these are the only troubles that may occur. The
following table denotes all warning/shutdown
conditions that the Compass Controller will sense.
Shutdown conditions will display the associated
message on the LCD, light the Compressor
Shutdown panel light, shut the system down, and
wait for operator to press the Fault/Reset button to
acknowledge the fault condition before a restart may
be attempted. Warning conditions display the
associated message on the LCD and light the
Compressor Warning panel light. Under a warning
condition the system will continue to operate
normally. In addition, the operator may dismiss the
warning message from the LCD screen by pressing
the “m” (mode) and “t” (trip) buttons on the master
gauge.
45
COMPASS CONTROLLER USER MANUAL SECTION 5

5.3 COMPASS CONTROLLER TROUBLESHOOTING GUIDE

Error Message Warning/Shutdown/ Description Recommended Action

Prevent Startup
No Message Prevent Startup No power or initialization of controller Turn OFF/ON/START
switch to ON position.
Make sure E-stop is not
engaged (pull out).
Turn Battery Disconnect
Switch to ON position.
Check Battery Voltage.
Check Connections
between Compass
Controller and harness
and at the starter and
harness.
Make sure Controller
internal circuit breakers
(4) are closed.
Listening For Engine Prevent Startup No communication between Compass Verify bus resistance at 120
Controller and engine ECM Ω.
Ensure proper
connection between
engine ECM and
Compass Controller.
Low Fuel Level Shutdown/Prevent Fuel Level Low Shutdown threshold Add fuel and restart.
Startup reached
P2 Signal Error Shutdown/Prevent Transducer has no source voltage Verify 5Vdc to transducer.
Startup Transducer has lost ground Verify path to ground.
Output voltage to controller is lost Verify .5-4.5Vdc to
controller.
Transducer malfunction Replace transducer.
Comp High Temp Shutdown/Prevent T1 Compressor temperature sensor is Verify thermistor
Startup above shutdown setpoint resistance between
803Ω @ -50˚C and
1573Ω @ 150˚C.
Coolers dirty Clean coolers.
Fan slipping Check/Adjust Fan belt
tension
Compressor Oil Thermostat Replace thermostat.
malfunction

46
SECTION 5 COMPASS CONTROLLER USER MANUAL

Error Message Warning/Shutdown/ Description Recommended Action

Prevent Startup
RTT High Shutdown/Prevent RTT (Receiver Tank Temperature) Verify compressor
Startup switch,normally closed, has opened temperature via
controller display (toggle
to proper parameter). If
compressor temp is less
than the setpoint on all
others then replace the
RTT switch.
Primary Shutdown Shutdown/Prevent Afterfilter restriction too high (filters Replace filters.
Startup dirty)
Afterfilters dp module malfunction Check source voltage
and ground and correct
if necessary.
Visually inspect for
damage and replace if
necessary.
Compass Comm Shutdown/Prevent Internal Cabling inside the Compass Open Controller and
Error Startup Controller is not properly connected ensure that all gauge
and warning bank
connectors are well
seated/engaged.
High Comp Pressure Shutdown/Prevent P1 (Dry) or P3 (Wet) pressure is above Pressure above 10 psi
Startup setpoint (recent shutdown). Wait
for pressure to fall below
10 psi.
Transducers out of calibration Transducers need to be
calibrated using the
Gauge calibration
subroutine (see Section
3.2.12).
Engine Overcrank Shutdown The maximum number of engine crank Check battery voltage &
cycles has been exceeded recharge if necessary.
Check starter relay for
short to ground.
Check source voltage to
starter relay.
Engine Comm Error Shutdown/Prevent The Compass Controller is not properly Check connections at
Startup receiving J1939 messages from the engine ECM and
engine ECM. Compass Controller.
Check the termination
resistor in the harness
ECM connector and
replace if necessary.

47
COMPASS CONTROLLER USER MANUAL SECTION 5

Error Message Warning/Shutdown/ Description Recommended Action

Prevent Startup
E-Stop Pressed Shutdown/Prevent The Compass Controller will not power Disengage E-stop.
Startup up/initialize (NO MESSAGE AT
CONTOLLER!)
The E-stop was used to shut machine Once conditions are
down. deemed safe, press the
Reset switch, Press the
OFF/ON/START switch
to OFF.
Eng Speed Too Low Shutdown Engine speed dropped below preset Check fuel level.
value for a preset amount of time. This
is to protect the vulcanized rubber drive Check the inlet valve for
coupling between the engine and premature opening during the
compressor. warmup phase.
P1,P2,P3 Signal Error Shutdown Error Loss of all transducer inputs Check voltage source and
during run phase ground for good connection.
Low Fuel Level Warning Fuel light in 4-in-1 gauge is on. Add fuel soon
Compressor warning light is on. Fuel
level is below 20%
Fuel Sender Error Warning The fuel level sensor signal is out of Check connections at
range sensor on tank. Verify
source voltage and
ground.
Wires possibly reversed.
Fuel sensor is defective.
Replace
Controller is configured
incorrectly (configured
for tank when no tank is
present). Reprogram
the Compass Controller
using the Compass
Controller
Communication
Software,
Communication
Adapter, and PC.
P1 Signal Error Warning Transducer has no source voltage Verify 5V dc to transducer.
Transducer has lost ground Verify path to ground.
Output voltage to controller is lost Verify .5-4.5 Vdc to controller.
Transducer malfunction Replace transducer.
P2 Signal Error Warning Transducer has no source voltage Verify 5V dc to transducer.
Transducer has lost ground Verify path to ground.
Output voltage to controller is lost Verify .5-4.5 Vdc to controller.
Transducer malfunction Replace transducer.

48
SECTION 5 COMPASS CONTROLLER USER MANUAL

Error Message Warning/Shutdown/ Description Recommended Action

Prevent Startup
P3 Signal Error Warning Transducer has no source voltage Verify 5V dc to transducer.
Transducer has lost ground Verify path to ground.
Output voltage to controller is lost Verify .5-4.5 Vdc to controller.
Transducer malfunction Replace transducer.
Air-Oil Separator Warning The differential pressure (P3 - P1) is Separator elements are
above the setpoint for the specified dirty. Replace.
period.
Aux Temp High Warning T2 (Aftercooler discharge temp or Clean coolers.
ambient
temp on non-aftercooled machines) Check/Adjust Fan belt
tension.
Check T2 (RTD) for
short circuit to ground.
Aux Temp Error Warning Check T2 (RTD) for
short circuit to ground or
open circuit.
Engine Air Filter Warning DP1 switch, normally closed, has Engine air filters clogged.
opened for the specified amount of Replace filters
time Check circuit for
continuity.
Check the air filter
switch for continuity.
Replace if open.
Comp Air Filter Warning DP2 switch, normally closed, has Engine air filters
opened for the specified amount of clogged. Replace filters.
time

Check circuit for

continuity
Check the air filter
switch for continuity.
Replace if open.
Primary Warning Warning Afterfilters restriction increasing service filters soon
(becoming clogged)
P4/P5 Signal Error Warning Afterfilters differential pressure signal Check connections between
module is encountering a malfunction the filter module and the two
pressure transducers (P4 &
P5) at the afterfilters
check source voltage and
ground to transducers and to
dp module
replace transducers
replace dp signal module

49
COMPASS CONTROLLER USER MANUAL
Error Message Warning/Shutdown/ Description
Prevent Startup
Louvers Closed Warning Informs operator of louver position.
AC Freeze Imminent Warning If the Compass Controller is configured
with an aftercooler and no louvers
installed and the temperature at the
discharge of the aftercooler falls below
the setpoint, this message is displayed.
Overflow Condition Warning A minimum service pressure must be
maintained to prevent overflowing the oil
separator filter. If the service pressure drops
below required value for a period of 15
seconds, Compass will override any throttle
control and command TSC1 to UCP Low
Engine Idle. “Overflow Condition” will be
displayed to inform end-user of condition.
The warning message can be end-user
acknowledged. Message acknowledgement
does not release TSC1 control.
Wait to Start Warning Message from CAT engine ECM.
J1939 Shutdown SPN1081 - Wait to
Start active
Oil Pressure Low Warning CAT DM1 Message (Engine ECM)
Coolant Temp High Warning CAT DM1 Message (Engine ECM)
50
SECTION 5
Recommended Action
None unless machine
overheats. Otherwise check
Ambient Temp Sensor reading
on LCD display. If the Ambient
Temp reading is higher than the
70°F and the louvers are closed,
check louver solenoid for proper
operation. Also check louver air
cylinders for proper operation. If
the Ambient Temp Sensor is
reading lower than atmospheric
conditions, then check the temp
sensor for proper operation and
replace is necessary.
Bypass the aftercooler
service air discharge circuit by
locking out the aftercooler from
the system and using non-
aftercooled air.
Install Louvers on the
aftercooler (if equipped)
or the canopy intake.
The service pressure must rise
above the programmed set
point, to normal operating
pressure, for longer than 5
seconds to clear the fault
condition. When the service
pressure returns above the set
point, throttle control reverts
back to previous method and
un-acknowledged warning
message will clear. The 300
PSI Compass set point is 85
PSI, 600 PSI Compass set
point is 150 PSI.
Check Engine ECM for active
codes/faults and possible
configuration errors. Contact
your nearest CAT servicing
dealer for resolution.
Check oil level and add if
necessary. If condition
persists, contact your nearest
CAT servicing dealer for
resolution
Check coolant level and
add if necessary. Clean
radiator if dirty. Check
fan belt tension and
tighten if needed.
SECTION 5 COMPASS CONTROLLER USER MANUAL

Error Message Warning/Shutdown/ Description Recommended Action

Prevent Startup
Eng. OverSpeed Warning CAT DM1 Message (Engine ECM) If problem persists, shut
machine down and
check for volatiles in the
atmosphere. Don’t
restart machine until
condition is removed. If
ECM still displays
message, contact your
nearest CAT servicing
dealer for resolution.
High Inlet Air Temp Warning CAT DM1 Message (Engine ECM) Check wind direction
and make sure
engine/package exhaust
is not being recirculated
to air intakes. Relocate
compressor if necessary.
Low Coolant Level Warning CAT DM1 Message (Engine ECM) Check coolant level and
add if necessary.
Check connection
between the coolant
level sensor and the
harness. Replace
sensor if necessary.
High Fuel Temp Warning CAT DM1 Message (Engine ECM) Make sure cooling air
intake is facing
prevailing winds. Make
sure all cooling air
openings in canopy are
not obstructed. Add fuel
if tank is near empty.
High Fuel Pressure Warning CAT DM1 Message (Engine ECM) Fuel delivery system
relief valve malfunction -
contact you local CAT
servicing dealer.

51
COMPASS CONTROLLER USER MANUAL SECTION 5

Error Message Warning/Shutdown/ Description Recommended Action

Prevent Startup
High Exhaust Temp Warning CAT DM1 Message (Engine ECM) Check wind direction
and make sure
engine/package exhaust
is not being recirculated
to air intakes. Relocate
compressor if necessary.
Exhaust valve timing
incorrect - Contact your
local CAT servicing
dealer

52
NOTES
 WWW.SULLAIR.COM

SULLAIR
3700 East Michigan Boulevard • Michigan City, Indiana, 46360 U.S.A.
Telephone: 1-219-879-5451

Printed in the U.S.A.

Specifications subject to change
without prior notice.
E12EP