.

DEALER MANUAL
K45-2 Engine Control Panel
FOR USE ON J1939 OR MECHANICAL
DIESEL ENGINES

K45-2 – Dealer Manual Dealer Manual-20110826 YJ_2.0VP.doc

Page 1 of 57
 .

Table of Contents
Table of Contents ...........................................................................................................2
1 General Warning ....................................................................................................4
2 Fly-back Diode Installation....................................................................................5
3 Considerations Prior to Operation .........................................................................5
4 Notes about this manual.........................................................................................6
5 Notes about the K45-2 ...........................................................................................6
6 Features of the K45-2 Control Panel .....................................................................6
7 Interface Panel .......................................................................................................7
7.1 Interface Button Layout .................................................................................7
7.1.1 The K45-2 Interface buttons / switches .................................................7
7.2 Interface LEDs and LCD Display..................................................................8
7.2.1 LCD display with back light ..................................................................8
7.2.2 Warning and Fault LEDs .......................................................................8
7.2.3 Manual mode LED.................................................................................8
8 Basic Operation......................................................................................................8
8.1 Starting the engine .........................................................................................8
8.1.1 Starting in manual start mode ................................................................8
8.1.2 Starting in automatic mode....................................................................9
8.1.3 Stopping the Engine ...............................................................................9
9 Menu Items and Setup .........................................................................................10
9.1 Main Display (RPM Screen)........................................................................10
9.2 Menu Screens...............................................................................................10
9.3 The Run Stop timer......................................................................................11
9.3.1 Setting the Stop timer...........................................................................11
9.3.2 Aborting the Stop timer .......................................................................11
9.4 Settings Menu ..............................................................................................13
9.4.1 Engine Parameters ...............................................................................14
9.4.2 Throttle Parameters (when Enabled) ...................................................18
9.4.3 4-20mA Sensor Parameters..................................................................22
9.4.3.1 Flow Parameters...............................................................................23
9.4.3.2 Pump Parameters .............................................................................24
9.4.4 Fuel Level Sender Parameters .............................................................26
9.4.5 Pump Oil Temperature Parameters ......................................................27
9.4.6 Pump Pressure #2.................................................................................28
9.4.7 Digital inputs........................................................................................30
9.4.8 Vacuum Priming ..................................................................................32
9.4.9 Flow Switch .........................................................................................34
9.4.10 Reset Fault History ..............................................................................36
9.4.11 Start Types ...........................................................................................37
9.4.12 MODBUS ............................................................................................38
9.4.12.1 MODBUS Communications ........................................................38
9.5 ECU Warnings and Faults ...........................................................................39
9.5.1 View Codes Present (No Fault Present)...............................................40
9.6 System Information......................................................................................41
9.7 Fault History ................................................................................................42
9.8 Engine Configuration...................................................................................42
10 Default Settings and Definitions......................................................................44
11 Troubleshooting (Fault Finding)......................................................................47
11.1 Serviceable Parts ..........................................................................................47

K45-2 – Dealer Manual Dealer Manual-20110826 YJ_2.0VP.doc

Page 2 of 57
 .

11.2 General .........................................................................................................48

11.3 LCD Display Faults .....................................................................................48
11.4 Power Faults.................................................................................................49
11.5 Tachometer Faults........................................................................................50
11.6 Engine Starting Faults..................................................................................50
11.7 Sensor Faults ................................................................................................51
11.8 Pump Pressure Faults ...................................................................................52
12 Appendix A: Run Process Diagram .................................................................53
13 Appendix B: K45-2 Menu Map .......................................................................54
14 Appendix C: Float Setup Examples.................................................................55
Limited Warranty.........................................................................................................56

Contact Details:

Kensho Pty Ltd,

17 Ari Drive, Campbellfield.
VIC. 3061. Australia.
ph: +61-3-9357-6550,
fax: +61-3-9357-6554

K45-2 – Dealer Manual Dealer Manual-20110826 YJ_2.0VP.doc

Page 3 of 57
 .

1 General Warning

Prior to Installation
- Remove all electrical power from controller and engine
- Ensure machine is safely secured during installation
- Check and follow all safety warnings and read all instruction manuals carefully
- Only use the controller for its intended purpose.

Prior to Engine Ignition

- Ensure that persons, engine and moving parts are free from obstruction.
- The user is responsible for ensuring the engine and controller are operated
safely. Any parameter or settings changes must be carried out by persons with
expert knowledge. Failure to do so may result in serious damage to equipment,
persons and may also void warranty.

K45-2 – Dealer Manual Dealer Manual-20110826 YJ_2.0VP.doc

Page 4 of 57
 .

2 Fly-back Diode Installation

All Inductive Loads (eg. Starter Solenoids, Fuel Stop Solenoids, Clutch Solenoids,
General Relays etc ) must be fitted with a fly-back diode such as the widely available
1N4005. The diode used must be of sufficient size in order to prevent damage from
reverse voltage spikes. A fly-back diode is sometimes also referred to as a snubber
diode, free-wheeling diode, suppressor diode, catch diode, or clamping diode.
The diode is fitted onto the source of the inductive load, normally in the engine wiring
loom.

FAILURE TO USE A FLYBACK DIODE MAY CAUSE DAMAGE TO THE

CONTROLLER AND WILL VOID WARRANTY.

Note:
If you have purchased this control panel with the engine, it is likely that the fly-
back diodes have been fitted to the engine wiring loom by the engine
manufacturer or panel installer. Ask your place or purchase to confirm that all
necessary diodes have been fitted.

3 Considerations Prior to Operation

• When mounting and during the life of the controller, please avoid subjecting
the controller to external elements including excessive heat, oil, dust,
vibration, and rain. It is mandatory that vibration mounts are used when
mounting the K45-2 control panel to an engine or engine base.
• High pressure cleaning devices must not be used and will likely cause damage
to the controller. Use a damp soft cloth to clean the face of the decal and
controller.
• Grounding of the controller must be carried out to prevent damage from
lightning strike.
• Persons under the influence of drugs and/or alcohol must not use controller or
operate any machinery.
• Maintenance of the engine must be carried out within the manufacturer’s
guidelines.
• Sensor wires must not be bundled with other wiring.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 5 of 57
 .

4 Notes about this manual

• Wherever the following symbol is shown, please check engine for obstruction,
debris, etc before proceeding. Ensure that it is safe to start engine

• Directions to press an interface button are all shown IN CAPITALS.

Eg: press MENU button
• Labels for Menu Items are shown in italics.

5 Notes about the K45-2

• Due to a service requirement every 100 hours for most applications, the stop
timer will not exceed this value.
• Always press the ENTER button to confirm any changes made. Not pressing
the ENTER button will not cause changes to take effect.
• It is important to set all changes/settings correctly – these are used to
determine the behavior of the K45-2 while the engine is running. Do not run
the engine without checking all values and settings. Factory set values
may not be applicable to your engine setup. Failure to do so may cause
damage to engine, controller or personnel.

6 Features of the K45-2 Control Panel

• Operates with both J1939 Electronic ECU and Mechanical Engines using applicable
wiring harness.
• Throttle Torque/Speed Control (TSC) for J1939 electronic engines or Mechanical
engine Speed Control via Linear Actuator with the ability to automatically ramp the
engine to a fixed speed.
• Engine Warm-Up and Cooldown timers with variable idle and RPM ramp rate.
• J1939 data providing Active Codes and Engine Configuration.
• Engine Fault History logging and display.
• Clear, large (4x20 Character) and easily visible Liquid Crystal Display shows Battery
Voltage, Engine RPM with Over Speed / Under Speed protection and Engine Hour
Meter.
• 7 x interface buttons for clear, easy control.
• Adjustable 100 Hour Run Timer.
• 1 x Fuel Level analogue input designed for VDO Fuel Level Senders.
• 4-20mA sensing for Flow or Pump Pressure with adjustable engine shutdowns for
Low Flow/Loss of Prime and Maximum Flow/Pump Pressure, with built-in Bypass
Timer and Slush Timer.
• 1 x 4-20mA Pump Discharge Pressure with adjustable engine shutdown setpoint,
built-in Bypass Timer and Slush Timer.
• Remote Start/Stop ability using external switching device eg. Water Float
• 1 x Relay output used to control ECU power or fuel stop solenoid including Energize
to Run or Energize to stop functionality.
• Analogue sensing for Pump Oil Temperature with Adjustable Setpoint.
• 1 x RS232/RS485 port for advanced data and configuration purposes.
• 1 x Speed detection input (Magneto, Magnetic Pickup or Alternator pulse detection)
used on mechanical engines.
• 3 x grounded digital inputs with individual re-naming capability.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 6 of 57
 .

7 Interface Panel
PANEL
7.1 Interface Button Layout ON/OFF

INC/DEC
TOGGLE

LIGHTS
ON/OFF

PANEL
FUSES

WARNING
/ FAULT
LEDs
7.1.1 The K45-2 Interface buttons / switches
Interface Button Purpose
MENU The MENU button allows access to the menu structure.
Pressing once while on the main screen enters the menu.
Further presses cycle back through the various menus.
DOWN The DOWN button allows for scrolling through menu
items and the decreasing of various values. This is
signified on the screen by ↓
UP The UP button allows for scrolling through menu items
and the increasing of various values. This is signified on
the screen by ↑
ENTER The ENTER button is used to alter values and confirm
changes. Pressing this button in the main menu will enter a
sub menu.
AUTO The AUTO button will place the K45-2 into Automatic
mode.
STOP The STOP button will stop the engine. The Engine
Cooldown Timer will commence. Pressing STOP a 2nd
time will bypass the cooldown timer.
MANUAL START The MANUAL START button will manually run the
engine by starting it immediately.

INC/DEC TOGGLE The INC/DEC toggle switch allows for a RPM trim
SWITCH adjustment between the Speed Select speed points.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 7 of 57
 .

7.2 Interface LEDs and LCD Display

7.2.1 LCD display with back light
The large character LCD unit will display all engine and controller data. The LED
backlight provides ease of operation in low light environments.

7.2.2 Warning and Fault LEDs

Colour/State K45-2 Status
Steady Amber Engine Warning.
Steady Red Engine Shutdown, Fault.

7.2.3 Manual mode LED

Used to indicate when the K45-2 is in manual mode (ie: has been powered on, but not
placed in automatic mode). This LED will remain lit until the unit is placed in
automatic mode by pressing the AUTO button.

8 Basic Operation
8.1 Starting the engine
As a general rule, auto-start functions and engine protection features are identical in
both manual start and automatic start modes, with the exception of the Stop Timer
function which will only operate in manual mode only. All bypass timers begin their
count down from engine start/running.

8.1.1 Starting in manual start mode

In manual mode the manual mode LED will be on.

Pressing the manual button will trigger the engine starting procedure, providing power
to the ECU or fuel solenoid and will show “Status:Starting“, along with a count down
timer on the display. This countdown timer is the same length as the glow period, if
used. On CAN J1939 engines a ‘Wait To Start’ message may appear.

The moment the engine starts an automatic bypass timer on all sensors is active. The
duration of this time can vary depending on how the K45-2 or ECU has been set up. A
minimum engine sensor lock out time of 20 seconds applies to all sensors accept for
low oil pressure, this is typically less than 20 seconds.
On a successful start the LCD display will show the engine RPM, Battery Voltage and
Engine Hours.
1500RPM 12.5VDC
125.0HRS
23PSI 40’C
Status: Running@Load
Main Display

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 8 of 57
 .

When the engine has started, the engine speed can be quickly adjusted by toggling the
increment/decrement switch. The idle and load speeds can be set and adjusted in the
controller software which can be accessed by pressing the MENU button, however
they may not be accessed whilst the engine is running.

8.1.2 Starting in automatic mode

To use the unit in Remote Auto-start mode the controller must be set in Auto Mode.
This is achieved by pressing the AUTO button. Once in auto mode the Manual mode
LED will be off and the display will show “Status:Auto:”.

To initiate a start in auto mode the Remote Start Input must be triggered. These are
two wires, usually brown and black, provided at the base of the controller.

The start input is either a maintained or momentary input. Please refer to the
schematic for your particular setup. The default setup is a maintained input. This is
user definable in User Settings Menu under Start Types.
Maintained operation is usually a “close to start / open to stop” setup. i.e.
while the contacts are closed the engine will be running. When the contacts are open
the engine will stop.
Momentary operation uses two (active ground) inputs in the controller to start
and stop the engine. The same Remote Start Input starts the engine and Remote Stop
Input stops the engine.

To avoid false starts the Remote Start Input must be closed for at least 4 seconds
before are crank to start will occur. If the Remote Start Input has been triggered the
display will show “Status:StartActive” and a countdown timer.
If the contactor opens before the elapsed timer the controller will wait for another start
signal. The slush timer on this input is useful when using single or two floats to start
and stop the engine.
If the timer reaches 0 the normal start procedure will occur as per in manual mode.

8.1.3 Stopping the Engine

Pressing the STOP button will stop the engine. To avoid stopping the engine abruptly
at high RPM or load, it is recommended the cool down timer is set. When the cool
down timer is initiated the engine will return to idle and then shutdown. In this case,
the engine RPM can not be manually adjusted.

1500RPM 12.5VDC
125.0HRS
Pls WAIT or hit STOP
Status: Cooldown 10

On any stop the shutdown screen above will appear. In the case of a mechanical style
engine the screen will appear until the engine RPM drops to zero and/or the
stabilization counter has elapsed. In the case of an electronic engine with an onboard
ECU, the shutdown period will last for the entire Stabilization timer. No other

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 9 of 57
 .

operations can be down during this time. The Stabilize period is a safeguard to the
ECU ignition input.

Sleep Mode
When the controller is waiting for a start and no buttons have been pressed for
approximately 10mins the K45-2 will go into sleep mode to conserve battery power.
The unit is still active but the backlight will be turned off.

9 Menu Items and Setup

9.1 Main Display (RPM Screen)

Engine RPM 1500RPM 12.5VDC Battery Voltage

Pump Pressure 2500KPA 125.0HRS Hours Meter
Engine Oil Pressure 23PSI 40’C Engine Temperature
System Status Status: OK

RPM, Battery voltage and engine hours are displayed at all times on the main display.
Depending on usage, extra engine data may be displayed on alternative screens that
can be displayed by pressing the
 buttons.

** Please Note: it is always good practice to return to the main RPM display
screen before starting as other information is displayed at various times.

9.2 Menu Screens

The K45-2 can be configured my accessing the menu items shown on the following
LCD screen.
MENU
>1. Set Stop Timer
2. General Settings
3. User Setting

MENU
4. View Active Codes
5. System Info
6. Fault History

MENU
7. Engine Config.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 10 of 57
 .

9.3 The Run Stop timer

The K45-2 features a 100 Hour Run Timer to limit the runtime of an engine. Once
initiated, the timer will count down the remaining time before shutting down the
engine.

9.3.1 Setting the Stop timer

The stop timer can be set either while the engine is running or stopped. This can be
accomplished through the following keystrokes:

• Press the MENU button once.

• The Screen will show:
MENU
>1. Set Stop Timer
2. General Settings
3. User Settings
• Press the
 buttons and select item 1. Set Stop Timer
• Press ENTER and the screen will show:

Set Stop Timer

hrs 05 : 00 mins

• Press the
 buttons to alter the hours. Press ENTER to save the changes.
• The screen will now show:

Set Stop Timer

hrs 05 : 30 mins

• Press
 buttons to alter the minutes. Press ENTER to save the changes.
• The screen will now return to the main menu.
• Press MENU to return to the RPM screen.
• The screen will now show:
1500RPM 12.5VDC
125.0HRS
Stop in - 05:30:29
Status: OK
The timer will commence when the engine has started and the K45-2 has detected
engine RPMs. The hourglass will be animated when the stop timer is active. Upon
completion, the engine will be stopped and the screen will show:
Normal : Shutdown

Timer Complete!

9.3.2 Aborting the Stop timer

The stop timer can be cancelled while the engine is running or stopped. This can be
accomplished through the following keystrokes:
• Press the MENU button once.
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 11 of 57
 .

• The Screen will show.

MENU
>1. Set Stop Timer
2. General Settings
3. User Settings
• Press the
and select item 1.
• Press ENTER and the screen will show.

Press ENTER to
Cancel Stop Timer

• Press MENU to return to the RPM screen.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 12 of 57
 .

9.4 Settings Menu

The Settings menu is password protected and should only be accessed by a qualified
and authorized user. These settings will define how the system will operate. Care
must be taken when changing settings as incorrect values may cause undesirable
results. Exit the settings completely and return to the main display before starting
engine.

• From the Main Display, press the MENU button.

• Press the
 buttons to select item 3. User Settings.
MENU
1. Set Stop Timer
2. General Settings
>3. User Settings
• Press ENTER. The screen will prompt for a password consisting of 4 values.

Enter Password
01: 01:01:01

• Use the
 buttons to enter the required value and press ENTER to proceed to
the next. Once all 4 have been set press ENTER
A correct password will allow access to the Setup Menu. For an incorrect password,
“Wrong password Please Re-enter” will momentarily appear and the screen will
return to the Settings Menu.
• Press
 to cycle through all available menu headings as per below
SETUP
>1. Engine
2. Throttle
3. 4-20mA Sensor

SETUP
4. Fuel Level
5. Pump Oil Temp.
6. Pump Pressure #2

SETUP
7. Vacuum Priming
8. Reset History
9. Start Types

SETUP
10. MODBUS

Each of these items is associated with different parameters described in detail below.
Please note, that at any time the MENU button can be pressed to exit any screen and
to return to the RPM screen. Refer to section 7.1.1 for the K45-2 Interface buttons /
switches functionality.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 13 of 57
 .

9.4.1 Engine Parameters

• To access Engine Parameters press the
 buttons and select item 1.Engine.
SETUP
>1. Engine
2. Throttle
3. 4-20mA Sensor
• Press ENTER, the screen will show:
Engine Parameters
1. Engine Run Speed
1800 rpm
Enter=Edit
=Select
• Press ENTER and then
 to alter the Engine Run Speed in RPM and ENTER
once again to save the value.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
2. Speed Source
J1939 ECU
Enter=Edit
=Select
• Press ENTER and then
 to change the Engine Speed Source from J1939
ECU for an electronic engine to Magnetic Pickup or Alternator for a
mechanical Engine. Press ENTER once again to save the setting. Note: It is
important to ensure the Engine Speed Source is correctly set. It is vital for
the correct operation of the K45-2.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
3. Flywheel Teeth
120 Teeth
Enter=Edit
=Select
• Press ENTER then
 to alter the number of teeth on the engine flywheel.
Press ENTER to save the value. This setting is only applicable when Magnetic
Pickup is selected as the Engine Speed source (see above). The K45-2 will not
use the Flywheel Teeth when an electronic J1939 ECU is in use.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
4. Pulses per REV
10.50 pulses
Enter=Edit
=Select
• Press ENTER then
 to alter the number of pulses from the alternator per
engine revolution. This setting is only applicable when Alternator is selected
as the Engine Speed source (see above). Press ENTER to save the value. The
K45-2 will not use the Pulses per REV when an electronic J1939 ECU is in
use.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
5. Underspeed
650 rpm
Enter=Edit
=Select
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 14 of 57
 .

• Press ENTER then
 to alter the engine Underspeed set point. Then press
ENTER once again to save the value. If the engine speed falls below this value
for a minimum of 4 seconds an engine shutdown will occur.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
6. Overspeed
1950 rpm
Enter=Edit
=Select
• Press ENTER then
 to alter the engine Overspeed set point. Then press
ENTER once again to save the value. If the engine speed rises above this value
for a minimum of 4 seconds an engine shutdown will occur.
Engine Parameters
7. Start Speed
650 rpm
Enter=Edit
=Select
• Press ENTER then
 to alter the engine Start Speed setpoint. Then press
ENTER once again to save the value. On a start of the engine when the engine
speed rises above this value a crank disconnect will occur.

• Press the  button to move to the next item. The screen will show:
Engine Parameters
8. Lockout Delay
30 secs
Enter=Edit
=Select
• Press ENTER then
 to alter the Engine Sensor Lockout Delay timer then
ENTER to save the value. When the engine starts and engine speed is
detected, the K45-2 will display sensor readings and will only enable engine
shutdowns after the sensor lockout time has expired.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
9. Crank Time
10 secs
Enter=Edit
=Select
• Press ENTER then
 to alter the Engine Crank Time then ENTER to save
the value. This value represents the maximum time that the K45-2 will crank
the engine on each start attempt. The engine will only crank for the full length
of time if it has not successfully started.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
10. Crank Rest Time
10 secs
Enter=Edit
=Select
• Press ENTER then
 to alter the Crank Rest Time then ENTER to save the
value. The timer will begin once the K45-2 ceases to crank the engine after an
unsuccessful start attempt. After this time has elapsed, the K45-2 may attempt
another crank attempt.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 15 of 57
 .

11. Crank Attempts

3
Enter=Edit
=Select
• Press ENTER then
 to alter the maximum number of attempts to start the
engine, then ENTER to save the value. If this number of unsuccessful crank
attempts is reached, the K45-2 will not attempt to start the engine again and
the screen will show:
Fault : Shutdown
Failed 3 Attempts

• Press the  button to move to the next item. The screen will show:
Engine Parameters
12. Glow Time
3 secs
Enter=Edit
=Select
• Press ENTER then
 to alter the period of time the Glow plugs are energized
before engine cranking, then ENTER to save the value. This is used to aid
engine starting in colder temperatures.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
13. Warm Up Time
0 mins
Enter=Edit
=Select
• Press ENTER then
 to alter the Engine Warm Up timer then ENTER to
save the value. The timer will begin when the K45-2 detects the engine has
started. The engine speed will be set to idle and cannot be adjusted until the
Warm Up time has expired.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
14. Cool Down Time
0 mins
Enter=Edit
=Select
• Press ENTER then
 to alter the Cool Down timer then ENTER to save the
value. The timer will begin when the K45-2 detects either an engine fault, a
request to switch the engine off, or the ignition switch is turned off. The
engine speed will be returned to idle for the Cool Down and a shutdown will
occur.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
15. Shutdown Timer
1 mins
Enter=Edit
=Select
• Press ENTER then
 to alter the Shut Down timer then ENTER to save the
value. The shutdown timer is used in applications when it is a requirement to
return a pump, compressor or generator to normal operating conditions prior to
the engine shutting down. The engine speed will be returned to idle and cannot
be adjusted until the timer is complete.
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 16 of 57
 .

• Press the  button to move to the next item. The screen will show:
Engine Parameters
16. Eng. Temp. Alarm
105’c
Enter=Edit
=Select
• Press ENTER then
 to alter the Engine Temperature Alarm then ENTER to
save the value. This is used as a secondary failsafe means for shutting the
engine down in the event of high engine temperature.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
17. Read Eng. Temp.
Mechanical Sender
Enter=Edit
=Select
• Press ENTER then
 to alter the Read Eng. Temp. value then ENTER to
save the value. This is used to choose where the engine temperature is read
from either a resistive temperature sender or from the J1939 CAN BUS.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
18.Eng OilPrs.Alarm
20PSI
Enter=Edit
=Select
• Press ENTER then
 to alter the Low Oil Pressure Alarm then ENTER to
save the value. This is used as a secondary failsafe means for shutting the
engine down in the event of low engine oil pressure.
• Press the  button to move to the next item. The screen will show:
Engine Parameters
19. Read Oil Prs.
Mechanical Sender
Enter=Edit
=Select
• Press ENTER then
 to alter the Read Oil Prs. value then ENTER to save the
value. This is used to choose where the engine oil pressure is read from either
a resistive oil pressure sender or from the J1939 CAN BUS.
• Press the  button to move to the next item. The screen will show:

Engine Parameters
20.Coolant Level
Disabled
Enter=Edit
=Select
• Press ENTER then
 to alter the Enable/Disable the Water Coolant Level
input, then ENTER to save the value. Where fitted, low Coolant Level
detection is used to shutdown the engine in the event of an inadequate level of
engine coolant.
• Press the  button to move to the next item. The screen will show:

Engine Parameters
21. Crank Assist

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 17 of 57
 .

10 counts
Enter=Edit
=Select
• Press ENTER then
 to alter the value of Crank Assistance, then ENTER to
save the value. A slight increase of the Crank Assist value may assist with
certain engine configurations that exhibit an inability to crank.
• Press the MENU button to move to the SETUP screen.

9.4.2 Throttle Parameters (when Enabled)

• To access Throttle Parameters Press the  button and select item 2.
SETUP

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 18 of 57
 .

1. Engine
>2. Throttle
3. 4-20mA Sensor
• Press ENTER and the screen will show:
Throttle Parameters
1. Throttle Type
Goto Fixed RPM
Enter=Edit
=Select
• Press ENTER then 
to Goto Fixed RPM (automatic throttling) then ENTER
to save the value. When automatic throttling is enabled, the engine can be
started and allowed to automatically reach a set RPM point. Manual RPM
adjustment is allowed when the engine has reached this set speed.
Alternatively, the Toggle Switch option may be used where automatic
throttling is not available.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters
2. Engine Idle
800 rpm
Enter=Edit
=Select
• Press ENTER then
 to alter the Engine Idle on engine startup, then ENTER
to save the value. An Autodetect option is available for J1939 ECU engines.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters
3. Line Fill Speed
1200 rpm
Enter=Edit
=Select
• Press ENTER then
 to alter the Line Fill Speed, then ENTER to save the
value. This function becomes active once the engine warm up period has
completed. Press the  button to move to the next item. The screen will show:
Throttle Parameters
4. Line Fill Time
2 mins
Enter=Edit
=Select
• Press ENTER then
 to alter the Line Fill Time, then ENTER to save the
value. The Line Fill time period will commence once the engine warm up
period has completed.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters
5. MaxRPM@Variable
1800 rpm
Enter=Edit
=Select
• Press ENTER then
 to alter the MaxRPM @Variable, then ENTER to save
the value. The MaxRPM@ Variable indicates how high the engine will throttle
to if Pump Pressure is not being achieved, when throttling with respect to
pressure i.e GO Variable.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 19 of 57
 .

5. MinRPM@Variable
1000 rpm
Enter=Edit
=Select
• Press ENTER then
 to alter the MinRPM @Variable, then ENTER to save
the value. The MinRPM@ Variable indicates how low the engine will throttle
to if a Pump Pressure above the target is being achieved, when throttling with
respect to pressure i.e GO Variable.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters
7.RPM Dead Zone
20 rpm
Enter=Edit
=Select

• Press ENTER then
 to alter the RPM Dead Zone, then ENTER to save the
value. The RPM Dead Zone indicates how close the desired and actual engine
rpm must be to be considered satisfactory.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters
8.Target Pressure
500KPA
Enter=Edit
=Select

• Press ENTER then
 to alter the Target Pressure or Flow as selected in 4-

20mA Sensors, then ENTER to save the value. The engine RPM will
automatically change to try and meet the Target Pressure or Flow.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters
9. Prs. Deadband
20KPA
Enter=Edit
=Select

• Press ENTER then
 to alter the Pressure or Flow Deadband as selected in 4-

20mA Sensors, then ENTER to save the value. The engine will automatically
stop throttling when the Pump Pressure or Flow is within +/- this value of the
Target.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters
10. J1939 INC Speed
20 rpm
Enter=Edit
=Select
• Press ENTER then
 to alter the RPM Increment Speed, then ENTER to
save the value. This is the rate at which the engine speed increases with each
increment.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters
11. J1939 DEC Speed
20 rpm

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 20 of 57
 .

Enter=Edit
=Select
• Press ENTER then
 to alter the RPM Decrement Speed, then ENTER to
save the value. This is the rate at which the engine speed decreases with each
decrement.
• Press the  button to move to the next item. The screen will show:

Throttle Parameters
12. Feedback Delay
0.5 secs
Enter=Edit
=Select
• Press ENTER then
 to alter the RPM Feedback Delay, then ENTER to save
the value. The Feedback Delay is used to adjust the RPM sensitivity when
altering engine speed.
• Press the  button to move to the next item. The screen will show:
Throttle Parameters
13. Ramp Rate RPM/sec
100
Enter=Edit
=Select
• Press ENTER then
 to alter the RPM Ramp Rate, then ENTER to save the
value. This is the rate at which the engine speed will increase once the engine
has started and the warm up timer has expired.
• Press the  button to move to the next item. The screen will show if GO
Variable has been selected in Throttle Type :
Throttle Parameters
14. Stagnant Time
1mins
Enter=Edit
=Select
• Press ENTER then
 to alter the Stagnant Time, then ENTER to save the
value. If Pressure or Flow is not achieved and the RPM is either at the
MaxRPM or MinRPM@Variable limit this timer will begin indicating the
pressure or flow value is not moving toward the target. This timer indicates
how long this state is acceptable. Once this timer has expired the engine will
perform a shutdown. This feature can de disabled by setting the time to
0mins.
• Press the  button to move to the next item. The screen will show if GO
Variable has been selected in Throttle Type :
Throttle Parameters
15. System Retries
3
Enter=Edit
=Select
• Press ENTER then
 to alter the System Retries value, then ENTER to save
the value. If the Stagnant Time has expired and the engine has shutdown and
restarted to achieve water pressure or flow, System Retries defines the amount
of times a restart will occur before a fault or latched shutdown is performed.

• Press the MENU button to move to the SETUP screen.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 21 of 57
 .

9.4.3 4-20mA Sensor Parameters

• To access 4-20mA Sensor Parameters Press the  button and select item 3.
SETUP
1. Engine
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 22 of 57
 .

2. Throttle
>3. 4-20mA Sensor

• Press ENTER and the screen will show:

4-20mA Sensor Type
>Flow Sensor
Pressure Sensor
Up/Down to Choose
• Press
 to alter the usage of the 4-20mA Sensor, and then ENTER to save
the setting.

9.4.3.1 Flow Parameters

Flow Parameters
1. Sender Function
Enabled
Enter=Edit
=Select
• Press ENTER then
 to Enable or Disable the Flow sensing function, then
ENTER to save the value.
• Press the  button to move to the next item. The screen will show:

Flow Parameters
2. SenderRange 4-20mA
200 L/S
Enter=Edit
=Select
• Press ENTER then
 to alter the Range of the 4-20mA Sender in use, then
ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Flow Parameters
3. Set Min. Flow
75 L/S
Enter=Edit
=Select
• Press ENTER then
 to alter the Minimum Flow Rate Alarm, then ENTER
to save the value. A lower rate of flow than this value will trigger an engine
shutdown.
• Press the  button to move to the next item. The screen will show:
Flow Parameters
4. Set Max. Flow
150 L/S
Enter=Edit
=Select
• Press ENTER then
 to alter the Maximum Flow Rate Alarm, then ENTER
to save the value. A flow rate in excess of this value will trigger an engine
shutdown.
• Press the  button to move to the next item. The screen will show:
Flow Parameters
5. Flow Bypass Time
3 mins
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 23 of 57
 .

Enter=Edit
=Select
• Press ENTER then
 to alter the Flow Rate Alarm Bypass Timer, then
ENTER to save the value. Upon engine startup, the K45-2 will display the
flow rate and the Flow Bypass Timer will commence. Engine shutdown due to
maximum or minimum flow rates will only be enabled after the bypass time
has expired.
• Press the  button to move to the next item. The screen will show:
Flow Parameters
6. Flow Slush Time
10 secs
Enter=Edit
=Select
• Press ENTER then
 to alter the Flow Slush Time period, then ENTER to
save the value. This value allows for a timer to commence upon detection of a
flow rate outside of the minimum or maximum permissible values before the
engine will be shutdown.

9.4.3.2 Pump Parameters

Pump Parameters
1. Sender Function
Enabled
Enter=Edit
=Select
• Press ENTER then
 to Disable, Enable or “Enable w. Start_Stop” the Pump
Pressure sensing function, then ENTER to save the value.
”Enable with Start Stop” when in Auto will enable the engine start and stop to
be controlled by Line Pressure start and stop points.
• Press the  button to move to the next item. The screen will show:

Pump Parameters
2. SenderRange 4-20mA
1000 KPA
Enter=Edit
=Select
• Press ENTER then
 to alter the Range of the 4-20mA Sender in use, then
ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Pump Parameters
3. Set Min Press.
200 KPA
Enter=Edit
=Select
• Press ENTER then
 to alter the Minimum Pump Pressure Alarm, then
ENTER to save the value. The low pump pressure or Loss of Prime
alarm/engine shutdown is set in this screen.

• Press the  button to move to the next item. The screen will show:
Pump Parameters
4. Set Max Press.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 24 of 57
 .

600 KPa
Enter=Edit
=Select
• Press ENTER then
 to alter the Maximum Pump Pressure Alarm, then
ENTER to save the value. A pump pressure in excess of this value will trigger
an engine shutdown. Press the  button to move to the next item. The screen
will show:
Pump Parameters
5. Pump Prs. Bypass
3min
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Pressure Alarm Bypass Timer, then
ENTER to save the value. Upon engine startup, the K45-2 will display the
pump pressure and the Pump Pressure Bypass Timer will commence. Engine
shutdown due to maximum or minimum pressure pump will only be enabled
after the bypass time has expired. Press the  button to move to the next item.
The screen will show:
Pump Parameters
6. Pump Prs. Slush
3 secs
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Pressure Slush Timer, then ENTER
to save the value. This value allows for a timer to commence upon detection of
a pump pressure outside of the minimum or maximum permissible values
before the engine will be shutdown. Press the  button to move to the next
item. The screen will show:
Pump Parameters
7. Calibration
50counts 0KPA
Enter=Edit
=Select
• Press ENTER then
 to alter the Calibration Counts then ENTER to save the
value. This value allows the operator to Zero the transducer and remove any
offset that may occur. Press the  button to move to the next item. The screen
will show:
Pump Parameters
8. Start Option
Start Low Stop High
Enter=Edit
=Select

• Press ENTER then
 to alter the Start Option then ENTER to save the value.
The controller can set set to Start on a Low pressure and Stop on a High
Pressure OR Start on a High Pressure and Stop on a Low Pressure.
Press the  button to move to the next item. The screen will show:

Pump Parameters
9. Start Pressure
300KPA
Enter=Edit
=Select

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 25 of 57
 .

• Press ENTER then
 to alter the Start Pressure then ENTER to save the
value. This is the trigger pressure to Start the engine.
Press the  button to move to the next item. The screen will show:

Pump Parameters
10. Stop Pressure
700KPA
Enter=Edit
=Select

• Press ENTER then
 to alter the Start Pressure then ENTER to save the
value. This is the trigger pressure to Stop the engine.

Please Note: The Start and Stop Pressures are usually set between the limits set in
SET MIN PRESS. & SET MAX PRESS.
Press the MENU button to exit the Pump Parameters.

9.4.4 Fuel Level Sender Parameters

Note: VDO Fuel Level Sender required. Refer to dealer for part numbers.
• To access Fuel Level Parameters press the  button and select item 4.
SETUP
>4. Fuel Level
5. Pump Temperature
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 26 of 57
 .

6. Flow Switch
• Press ENTER and the screen will show:
Fuel Level Setup
1. Fuel Alarm Point
Disabled
Enter=Edit
=Select
• Press ENTER then
 to alter the Low Fuel Level Alarm percentage (%), then
ENTER to save the value. This is the percentage of fuel remaining in the fuel
tank which will trigger a warning or engine shutdown. Press the  button to
move to the next item.

The screen will show:

Fuel Level Setup
2. Alarm Action
Warning
Enter=Edit
=Select
• Press ENTER then
 to alter the Low Fuel Level Alarm Action type, then
ENTER to save the value. The alarm action can be set to either WARNING or
engine SHUTDOWN. Press the  button to move to the next item. The screen
will show:
Fuel Level Setup
3. Fuel Sender Type
Float or Arm Type
Enter=Edit
=Select
• Press ENTER then
 to alter the Fuel Sender Type, then ENTER to save the
value. The options are: Tubular Sender or Float or Arm Type. The Fuel
senders used are manufactured by VDO. Press the  button to move to the
next item. The screen will show:

Fuel Level Setup

4. Fuel Calibration
82 Counts
Enter=Edit
=Select
• Press ENTER then
 to alter the Fuel Calibration Count, then ENTER to
save the value. The menu allows for the use of two types of VDO fuel level
senders by altering a calibration value. Press the MENU button to move to the
SETUP screen.

9.4.5 Pump Oil Temperature Parameters

• To access Pump Oil Temp. Parameters press the  button and select item 5.
SETUP
4. Fuel Level
>5. Pump Oil Temp.
6. Pump Pressure # 2
• Press ENTER and the screen will show:
Pump Temp. Param.
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 27 of 57
 .

1. Pump Temp. Alarm

Disabled
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Temperature Enable/Disable, then
ENTER to save. Press  to move to the next item. The screen will show:
Pump Temp. Param.
2.PumpTemp Setpoint
40’c
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Temperature Alarm, then ENTER to
save the value. Press the MENU button to move to the SETUP screen.

9.4.6 Pump Pressure #2

For Discharge Pressure usage.
• To access Pump Pressure #2 press the  button and select item 6.
SETUP
4. Fuel Level
5. Pump Oil. Temp
>6. Pump Pressure #2
• Press ENTER and the screen will show:
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 28 of 57
 .

Pump Prs2 Parameters

1. Sender Function
Enable
Enter=Edit
=Select
• Press ENTER then
 to alter the Range of the 4-20mA Sender in use, then
ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Pump Prs2 Parameters
2. SenderRange 4-20mA
750 KPA
Enter=Edit
=Select
• Press ENTER then
 to Enable or Disable second Pumping Pressure Sender
sensing, then ENTER to save the value.
• Press the  button to move to the next item. The screen will show:

Pump Prs2 Parameters

3. Set Min Press.
200 KPA
Enter=Edit
=Select
• Press ENTER then
 to alter the Minimum Pump Pressure Alarm, then
ENTER to save the value. The low discharge pressure or Loss of Prime
alarm/engine shutdown is set in this screen.
• Press the  button to move to the next item. The screen will show:
Pump Prs2 Parameters
4. Set Max Press.
600 KPa
Enter=Edit
=Select
• Press ENTER then
 to alter the Maximum Discharge Pump Pressure Alarm,
then ENTER to save the value. A pump discharge pressure in excess of this
value will trigger an engine shutdown. Press the  button to move to the next
item. The screen will show:
Pump Prs2 Parameters
5. Pump Prs.2 Bypass
3min
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Discharge Pressure Alarm Bypass
Timer, then ENTER to save the value. Upon engine startup, the K45-2 will
display the pump pressure and the Pump Pressure Bypass Timer will
commence. Engine shutdown due to maximum or minimum pressure pump
will only be enabled after the bypass time has expired. Press the  button to
move to the next item. The screen will show:
Pump Prs2 Parameters
6. Pump Prs.2 Slush
3 secs
Enter=Edit
=Select

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 29 of 57
 .

Press ENTER then
 to alter the Pump Discharge Pressure Slush Timer, then
ENTER to save the value. This value allows for a timer to commence upon detection
of a pump pressure outside of the minimum or maximum permissible values before
the engine will be shutdown. Press the MENU button to move to the SETUP screen

9.4.7 Digital inputs

• To access Digital Inputs press the  button and select item 7.
SETUP
> 7. Digital Inputs
8. Vacuum Priming
9. Flow Switch
• Press ENTER and the screen will show:
Digital Inputs
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 30 of 57
 .

1.Bearing Temp Swt

Enabled
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Bearing Temperature Function to
Enable or Disabled, then ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Digital Inputs
2. Bearing Temp Swt
Normally Closed
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Bearing Temperature Input type to
Normally Closed or Normally Open, then ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Digital Inputs
3. Pump Oil Lvl Swt
Enabled
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Oil Level Function to Enable or
Disabled, then ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Digital Inputs
4. Pump Oil Lvl Swt
Normally Closed
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Oil Level Input type to Normally
Closed or Normally Open, then ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Digital Inputs
5. Pump Clutch Input
Enabled
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Clutch Function to Enable or
Disabled, then ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Digital Inputs
5. Pump Clutch Input
Normally Open
Enter=Edit
=Select
• Press ENTER then
 to alter the Pump Clutch Input type to Normally Closed
or Normally Open, then ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Digital Inputs
6.Water Loss Input
Enabled
Enter=Edit
=Select
• Press ENTER then
 to alter the Water Loss Function to Enable or Disabled,
then ENTER to save the value.
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 31 of 57
 .

• Press the  button to move to the next item. The screen will show:
Digital Inputs
6.Water Loss Input
Normally Closed
Enter=Edit
=Select
• Press ENTER then
 to alter the Water Loss Input type to Normally Closed
or Normally Open, then ENTER to save the value.

9.4.8 Vacuum Priming

• To access Vacuum Priming press the  button and select item 8.
SETUP
7. Digital Inputs
> 8. Vacuum Priming
9. Flow Switch
• Press ENTER and the screen will show:
Vacuum Priming
1. Vac. Function

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 32 of 57
 .

Disabled
Enter=Edit
=Select
• Press ENTER then
 to alter the Vacuum Priming Function to Enable or
Disabled, then ENTER to save the value.
• Press the  button to move to the next item. The screen will show:
Vacuum Priming
2. Slush Time
4 secs
Enter=Edit
=Select
• Press ENTER then
 to alter the Vacuum Priming Slush Time, then ENTER
to save the value. The Slush Time affects the “ Vac. Water Loss” and the ”
Accum Pump Clutch” Digital Inputs which in there normal state are Normally
Closed. These inputs must see the alternate state (OPEN) for the set slush
time before the “Bypass Time” begins to count down and Clutch Relay R9
will be engaged.
• Press the  button to move to the next item. The screen will show:
Vacuum Priming
3. Bypass Time
6 mins
Enter=Edit
=Select
• Press ENTER then
 to alter the Vacuum Priming Bypass Time. , then
ENTER to save the value. The Bypass Time will begin countdown when the
“Vac. Water Loss” input and the “Accum Pump Clutch Inputs” are triggered.
If water pressure/flow has not been sensed and the Bypass time has elapsed the
engine will commence a controlled shutdown.

Vacuum Priming Function Screen

From the Main RPM press the
button to view the Vacuum Priming status.
Vacuum Priming: OFF
Water Level : LOW
Pump : OFF
Timer: 06:00
If the Function is enabled and the “Vac. Priming” toggle switch on the front of
the panel is ON the “Vacuum Priming” status will show “ON”.
If the Vac. Water Loss Input is in its normal state i.e. water present the “Water
Level” will show : HIGH else, if the input is triggered (OPEN) it will show
“LOW”.

If the “Vac. Water Loss” input is LOW and the Accum. Pump Clutch Inputs is
triggered the clutch will be engaged and the status will Show PUMP: ON.
Once water has returned the clutch will turn OFF and the Pump status will also
show Pump OFF.

The Timer, when counting down, is indicating that the water is low and the
pump is on. If the timer reaches 00:00 the engine will shutdown.
If water returns, the timer will reset to the set time Timer: 06:00
Please note: The displayed timer does not indicate the flow switch timer only
the Vacuum Timing Function.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 33 of 57
 .

9.4.9 Flow Switch

• To access Vacuum Priming press the  button and select item 8.
SETUP
7. Digital Inputs
8. Vacuum Priming
>9. Flow Switch
• Press ENTER and the screen will show:
Flow Switch Param.
1. Flow Switch Bypass
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 34 of 57
 .

Disabled
Enter=Edit
=Select
• Press ENTER then
 to alter the Flow Switch Bypass Timer, then ENTER to
save the value. Upon engine startup, the panel will bypass the Flow Switch
until the Bypass Timer has expired. If the Bypass Timer is set, engine
shutdown due to a flow switch fault will only be enabled after the bypass time
has expired.
• Press the  button to move to the next item. The screen will show:
Flow Switch Param.
2. Flow Slush Timer
10 secs
Enter=Edit
=Select
• Press ENTER then
 to alter the Flow Switch Slush Timer, then ENTER to
save the value. This value allows for a timer to commence upon detection of a
flow switch fault before the engine will be shutdown.
• Press the  button to move to the next item. The screen will show:
Flow Switch Param.
3. Flow Switch Type
Normally Closed
Enter=Edit
=Select
• Press ENTER then
 to alter the Flow Switch Type, then ENTER to save the
value. A Normally Open or Normally Closed Flow Switch type may be used.
• Press the  button to move to the next item. The screen will show:
Flow Switch Param.
4. Shutdown Type
Controlled
Enter=Edit
=Select
• Press ENTER then
 to alter the Flow Switch Shutdown Type, then ENTER
to save the value. This value allows for either an Immediate or Controlled
engine shutdown to occur upon Flow Switch fault. A Controlled shutdown
will allow a cooldown period to expire, an Immediate shutdown type will not.
• Press the  button to move to the next item. The screen will show:
Flow Switch Param.
5. Input Type
Passive
Enter=Edit
=Select
• Press ENTER then
 to alter the Flow Switch Input Type, then ENTER to
save the value. The settings available are Active, allowing a powered Flow
Switch to be used, and Passive, allowing an un-powered switch-type Flow
Switch to be used.
• Press the  button to move to the next item. The screen will show:
Flow Switch Param.
6. Latched Shutdown
Shutdown Latched
Enter=Edit
=Select

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 35 of 57
 .

• Pressure ENTER then
 to alter the Latched shutdown enable, then ENTER
to save the value. This value allows for either a latched shutdown or non-
latched shutdown to occur upon Flow Switch fault.
• Press the MENU button to move to the SETUP screen.

9.4.10 Reset Fault History

This menu is used to delete fault codes generated prior to an engine or machine repair.
• To access Reset History press the  button and select item 8.
SETUP
>10. Reset History
11. Start Types

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 36 of 57
 .

12. Modbus
• Press ENTER and the screen will show:
Press Enter to Reset
the Fault History
or Menu to Exit

• Press ENTER to reset the fault history or MENU to exit.

9.4.11 Start Types

This menu is used to setup the K45-2 Panel’s Remote Start and Stop functionality and
the Fuel Relay control.
• To access the Start Types menu press the  button and select item 9.
SETUP
10. Reset History
>11. Start Types
12. Modbus
• Press ENTER and the screen will show:
Start Parameters
1.Set Start Type
Maintained
Enter=Edit
=Select
• Press ENTER then
 to alter the Type of trigger used for the Remote Start
input, then ENTER to save the value. The options are “Maintained”, requiring
the trigger to remain active for the duration of the engine runtime, and
Momentary, which allows the trigger to deactivate once the engine has started.
• Press the  button to move to the next item. The screen will show:
Start Parameters
2. Input Type
Start NO Stop NO
Enter=Edit
=Select
• Press ENTER then
 to alter the Type of trigger used for the Remote Start
and Stop inputs, then ENTER to save the value. Four combinations allow for
Start and Stop to use Close on Rise (CR) or Close on Fall (CF).
(See Section 14 Appendix C for Float Setup usage examples.)
• Press ENTER and the screen will show:
Start Parameters
3. Fuel Relay Ctrl.
Energize to Run
Enter=Edit
=Select
• Press ENTER then
 to alter the Fuel Relay type, then ENTER to save the
value. In an Energize to Run system the Fuel Relay is energized whilst the
engine is in operation and de-energized upon engine shutdown. In an Energize
to Stop system, the Fuel Relay is de-energized whilst the engine is in operation
and energized upon engine shutdown.
• Press the MENU button to move to the SETUP screen.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 37 of 57
 .

9.4.12 MODBUS

9.4.12.1 MODBUS Communications

In “User Settings” the MODBUS Setup Screens can be accessed in
SETUP
10. Reset History

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 38 of 57
 .

11. Start Types

>12. Modbus
MODBUS data can be acquired from the controller for SCADA, PLC or any other
MODBUS compliant telemetry system. The controller is the SLAVE in the
MODBUS relationship. A register list of all controller data is available on request. It
is recommended that all registers are polled at once with at a baud rate 19200 or 9600,
8 data bits, 1 stop bit, No Parity.
Press ENTER and the screen will show:
Modbus
Active
RS232
Enter=Edit
=Select
• Press ENTER then
 to alter the Communication Protocol. The controller
can be configure for RS232 or RS485. Press ENTER to save the value.
Press  to move to the next item.
Modbus
Slave Address
010
Enter=Edit
=Select

• Press ENTER then
 to alter the Slave Address. The controller has a unique
address in the MODBUS chain which can be configured between 0 and 250.
Press ENTER to save the value.
Press  to move to the next item or MENU to Exit

9.5 ECU Warnings and Faults

When used with a J1939 Electronic Engine ECU the K45-2 is able to display
Warnings and Faults that are sent over the CAN BUS: For example:
1500RPM 12.5VDC
125.0HRS
__23PSI 105’C
Status: ECU Warning!

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 39 of 57
 .

The amber LED will illuminate when a warning message is generated. The message
will not be cleared until the engine problem is rectified. The K45-2 will not shutdown
on an “ECU Warning!”, however, the ECU will shut the engine down itself if an
“ECU Stop!” occurs. The ECU is permitted to self-protect and the “ECU Stop!” will
be logged in the K45-2. The red LED will illuminate when an engine shutdown
message is generated. If a warning or stop is present, the faults can be viewed in the
“View Active Codes” menu.

If there are more than one code present, pressing the ENTER button will go to the
next code available. If there is more than one code present you may have to go out of
this screen and return to it to view current information.

9.5.1 View Codes Present (No Fault Present)

• To access View Active Codes press the  button and select item 3.

MENU
1. Set Stop Timer
2. User Settings
>3. View Active Codes

• Press ENTER and the screen will show:

No Active

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 40 of 57
 .

Fault Codes

• If there are no active codes broadcasted from the engine’s ECU, the screen
will show NO ACTIVE FAULT CODES.
• View Active Codes (Fault(s) Present)
• Any fault codes and messages generated by the engine’s ECU will be
displayed by the K45-2 Control Module.
• Press ENTER and the screen will show: For example:

SPN:110 FMI: 3
OC: 1 1/1
Eng Coolant Temp. High

• If active codes are present the screen will show the SPN (Suspect Parameter
Number), FMI (Failure Mode Identifier), OC (Occurrence Count) and a
description of the fault.
• If multiple messages exist then the 1 of 1 (1/1) will be altered to 1 of 2 or 1 of
3 etc. To view multiple messages press ENTER to view each message.Press
the MENU button to move to the SETUP screen.

Note:
An active code can only be cleared by the ECU once the problem has been rectified.
The K45-2 Control Module treats ECU warnings for oil pressure and engine
temperature as shutdowns. The K45-2 will not permit an engine start if the oil and
engine temperature sensors are faulty or disabled.

9.6 System Information

This menu provides basic information regarding the controller setup.
• To access the System Information Parameters press the  button and select
item 4.
MENU
>4. System Info
5. Fault History
6. Engine Config.

• Press ENTER and the screen will show:

Serial Number
373

• Press ENTER and the screen will show:

Build Date
20110401

• Press ENTER and the screen will show:

K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 41 of 57
 .

Firmware Version
V1.98VP

• Press ENTER and the screen will return to the MENU screen.

9.7 Fault History

• To access the Fault History Information press the and select item 5.
MENU
4. System Info
>5. Fault History
6. Engine Config.
• Press ENTER and the screen will show all previous faults generated by the
pump, generator, or compressor attached to the engine. For example:
Bad or No RPM

Occurrence: 1

• Continue to press ENTER until all faults are shown and the screen returns to
the MENU screen.

9.8 Engine Configuration

• To access the Engine Configuration Information press the  button and select
item 6. The Engine Configuration menu is for use with J1939 Electronic ECU
engines. It enables the user to view the various RPM setpoints configured
within the ECU.
MENU
4. System Info
5. Fault History
>6. Engine Config.
• Press ENTER and the Screen will now show:
Engine Speed Pt1
@ Idle 0 rpm

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 42 of 57
 .

This screen shows the Engine Speed Setpoint 1 value for Idle.
• Press ENTER and the Screen will now show:
Torque @ Idle
Pt1 131%

This screen shows the Engines Torque output at Engine Speed Setpoint 1 for idle.
• Press ENTER and the Screen will now show:
Engine Speed Pt2
0 rpm

This screen shows the Engine Speed Setpoint 2 value.

• Press ENTER and the Screen will now show:
Torque Pt2
131%

This screen shows the Engines Torque output at Engine Speed Setpoint 1 for idle.
• Press ENTER repeatedly to view Setpoint 3, Setpoint 4, and Setpoint 5 values.
Following these, the Screen will show:
Engine Speed @High
Idle Pt6 0 rpm

This screen shows the Engine Speed @ High Idle Setpoint 6.

• Press ENTER and the Screen will now show:
Gain KP Endspeed
Governor 0%

This screen shows the Gain in KPa. Press ENTER and the Screen will now show:

Reference Engine
Torque 0 Nm

This screen show the Engine Torque reference value.

• Press ENTER and the Screen will now show:
Max Engine O/Spd
Pt 7 0 rpm

This screen shows the Maximum Engine Overspeed Setpoint 7 value.

• Press ENTER and the Screen will now show:
Max Mom Engine
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 43 of 57
 .

Override 0 secs

This screen shows the Maximum Momentary Engine Override value.

• Press ENTER and the Screen will now show:
Req. Spd. Control
Low Lim. 0 rpm

This screen shows the Requested Speed Control Lower Limit value.
• Press ENTER and the Screen will now show:
Req. Spd. Control
High Lim. 0 rpm

This screen shows the Requested Speed Control High Limit value.
• Press ENTER and the Screen will now show:
Req. Torque Cntrl
Low Limit 131%

This screen shows the Requested Torque Control Lower Limit value.
• Press ENTER and the Screen will now show:
Req. Torque Cntrl
High Limit 131%

This screen shows the Requested Torque Control High Limit value.

10 Default Settings and Definitions

Item Setting Variable Default Range Change Function Description
Value Amount
1 Engine Run Speed 1800RPM 1000 to 25 RPM Desired speed of engine at load
4000RPM
2 Speed Source Alternator J1939/Magnetic - Use J1939 for an Electronic ECU Engine,
Pickup/Alternator Magnetic Pickup or Alternator for a Mechanical
Engine.
3 Flywheel Teeth 120 teeth 60 to 190 teeth 1 tooth Number of teeth on the engine flywheel when
a Magnetic Pickup Speed Source is used for a
Mechanical Engine.
4 Pulses Per Revolution 10.50 pulses 2.00 to 25.00 0.02 Number of Pulses from Alternator for 1
Pulses/Revolution Revolution of the engine. Use when Alternator
is selected as Speed Source for Mechanical
Engine.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 44 of 57
 .

5 Under speed 650RPM 550 to 2000RPM 25 RPM Engine overload slow speed protection with
slush delay of 5secs.
6 Over speed 1950RPM 1000 to 25 RPM Engine high speed protection with slush delay
4000RPM of 5secs
7 Start Speed 600rpm 400 to 2000RPM 25RPM Digital and analogue sensor shutdown bypass
timer on engine startup.
8 Lockout delay 30secs 20 to 60secs 1 sec Digital and analogue sensor shutdown bypass
timer on engine startup.
9 Crank Timer 10secs 5 to 20secs 1sec Maximum time engine will crank on a start
attempt.
10 Crank Rest Timer 10secs 5 to 60secs 1sec Allows engine to rest after an unsuccessful
start attempt before retry.
11 Crank Attempts 3 attempts 3 to 10 attempts 1 Allows engine to retry after a failed start
attempt.
12 Glow Timer 3sec 0 to 20secs 1 Time to energize Glow plug(s) when starting
engine as an aid in cold temperatures.
13 Warm Up Timer 0 mins 0 to 20 mins 10 min Allows engine to warm up at idle prior to
throttling at full load.
14 Cool Down Timer 0 mins 0 to 20 mins 1 min Allows engine to cool down to idle after
operating at full load.
15 Shutdown Timer 1mins 0 to 20mins 1 min Allows engine to cool down to idle after a
Pump fault has occurred.
16 Engine Temp Alarm 105’C 0 to 200’C 1 'C If the Engine Coolant temperature rises above
this value the engine will be immediately
shutdown.
17 Read Eng. Temp Mechanical Mechanical -- Source of Engine Coolant Temperature --
Sender Sender or J1939 Resistive sender or J1939 CAN BUS value.
ECU
18 Engine Oil Pressure 20PSI 0 to 144PSI 1 PSI If the Engine Oil Pressure falls below this
Alarm value the engine will be immediately
shutdown.
19 Read Oil. Prs. Mechanical Mechanical -- Source of Engine Oil Pressure -- Resistive
Sender Sender or J1939 Sender or J1939 CAN BUS value.
ECU
20 Engine Coolant Level Disabled Disabled to - Allows Low Engine Water Coolant Level
Enabled detection with 5sec slush before Engine
Shutdown.
21 Crank Assist 10counts 0 to 150counts 1 count Allows engines that exhibit rpm faults to
extend their initial crank time.

Item Setting Variable Default Range Change Function Description

Value Amount
Throttle
Parameters
1 Throttle Type Go to Fixed Disabled to Go to - Enables automatic engine throttling to fixed
RPM Fixed RPM speed or Variable RPM
2 Engine Idle 800 Auto detect to 25 RPM Idle Speed Select for engine startup speed.
1200RPM
3 Line Fill Speed 1200RPM 900 to 2000 RPM 25 RPM After the warm up timer has elapsed the
engine (when in auto) will throttle to this
speed for the adjustable time set to fill
irrigation lines.
4 Line Fill Time 2min. 0 to 20mins 1 min After the warm up timer has elapsed the
engine (when in auto) will throttle to Line Fill
Speed for the adjustable time set to fill
irrigation lines.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 45 of 57
 .

5 MaxRPM@ Variable 1800RPM 900 to 4000RPM 25 RPM When in Variable and pump pressure is not
achieved this is the maximum RPM the engine
will throttle to.
6 MinRPM@ Variable 1000RPM 900 to 4000RPM 25 RPM When in Variable and pump pressure is
achieved this is the minimum RPM the engine
will throttle to.
7 RPM Dead Zone 20RPM 10 to 200RPM 10 RPM When the engine speed is changing the
throttle will cease to alter once the real time
speed is within +/- the RPM dead zone of the
target RPM
8 Target Pressure 500KPA 0 to 3200KPA 10KPA When in Variable the Target Pressure the
system is trying to achieve

9 Pressure Deadband 20KPA 10 to 300KPA 5KPA When the engine speed is changing the
throttle will cease to alter once the real time
pressure is within +/- the pressure dead zone
of the target Pressure
10a J1939 INC Speed 20RPM/SEC 10 to 10 RPM When throttling to idle, line fill speed, fixed
(ECU electronic 250RPM/Sec speed or max/min RPM this defines the
engines) incremental rate at which the throttle will
increase.
11a J1939 DEC Speed 20RPM/SEC 10 to 10 RPM When throttling to idle, line fill speed, fixed
(ECU electronic 250RPM/Sec speed or max/min RPM this defines the
engines) decremented rate at which the throttle will
decrease.
10b Linear INC Speed 20% 10 to 100% 1% When throttling to idle, line fill speed, fixed
speed or max/min RPM this defines the
incremental rate at which the throttle will
increase.
11b Linear Dec Speed 20% 10 to 100% 1% When throttling to idle, line fill speed, fixed
speed or max/min RPM this defines the
decremented rate at which the throttle will
decrease.
12 Feedback Delay 0.2sec. 0.5 to 4.0secs 0.1 sec When throttling to idle, line fill speed, fixed
speed or max/min RPM this defines the delay
between throttling steps to allow the pump or
genset system to respond.
13 Throttle Ramp Rate 100RPM/SEC 10 to 10 RPM Engine speed rate of increase at engine
600RPM/Sec startup, normally after warm up and line fill
timer.
14 Stagnant Time 1min 0 to 20mins 1min When in Variable, if the target is not achieved
and the RPM is at MIN or MAXRPM for the
stagnant time, the system has become
stagnant and the engine will shutdown.
Set to 0mins to Disable.
15 System Retries 3 0 to 20 1 The amount of times the engine will restart
when the system becomes stagnant before a
latched shutdown occurs.
4-20A Flow Sensor

1 Sender Function Disabled Enable or - Enable/Disable the 4-20mA Sender.

Disabled
2 4-20mA Flow Sender 300L/S 0 to 5 L/S Maximum reading of 4-20mA Sender.
Max Range 1000Litres/Sec
3 4-20mA Minimum 75 L/S 10 to Maximum 5 L/S Minimum Flow rate for Shutdown.
Flow
4 4-20mA Maximum 245 L/S Min to Range 5 L/S Maximum Flow rate for Shutdown.
Flow
5 4-20mA Flow Bypass 3 min 1 to 60mins 1 min Startup bypass time before shutdowns are
Timer enabled.
6 4-20mA Flow Slush 10 sec 10 to 60secs 1 sec Slush time before shutdown occurs.
Timer
4-20mA Pressure
Sender

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 46 of 57
 .

1 Sender Function Disabled Enable or - Enable/Disable the 4-20mA Sender.

Disabled
2 4-20mA Pump 1000KPa 0 to 3200KPa 10 KPa Maximum reading of 4-20mA Sender.
Pressure Sender Max
Range
3 4-20mA Min Pump 200KPa Min to Range 10 KPa Minimum Pump Pressure Shutdown
Pressure
4 4-20mA Max Pump 800KPa Min to Range 10 KPa Maximum Pump pressure or High Discharge
Pressure Shutdown
5 4-20mA Pump 3mins 1 to 60mins 1 min Startup bypass time before shutdowns are
Pressure Bypass timer enabled.
6 4-20mA Pump 10secs 10 to 60 seconds 1 sec Slush time before shutdown occurs.
Pressure Slush timer
Fuel Level

1 Fuel Level Alarm Point Disabled Disabled to 99% 1% Enabling low fuel level monitoring using VDO
sender as a percentage of 100.
2 Fuel Level Alarm Warning Warning to - Enabling low fuel level warning or engine
Action Shutdown shutdown.
3 Fuel Level Sender Tubular Tubular Sender - Select type of fuel level sender to be used
Type Sender to Float or Arm from VDO range.
Type
4 Fuel Level Sender 82 Counts 10 to 254 1 count Allows K45-2 calibration for fuel level sender
Calibration from VDO range.
Pump Oil
Temperature
1 Pump Temperature Disabled Disable to Enable - Enabling Pump Temperature shutdown.
Alarm
2 Pump Temperature 40°C 10 to 145°C 1°C Maximum allowable operating Pump
Setpoint Temperature.
System Control

1 Remote Start Type Maintained Maintained to - Trigger type for a remote start input.
Momentary Maintained type will remain activated,
Momentary will activate and deactivate.
2 Remote Start Input Start NO Close to Rise/ - Start Trigger may be Close to Rise or Close to
Type Stop NO Close to Fall Fall. Stop Trigger may be Close to Rise or
Close to Fall.
3 Fuel Relay Control Energize to Energize to - Engine Fuel Solenoid may remain energized or
Run Run/Energize to de-energized during engine running.
Stop

11 Troubleshooting (Fault Finding)

It is important to comply with the engine manufacturers safety recommendations
when troubleshooting the controller. The troubleshooting information provided is for
reference only. Only authorized and trained personnel should diagnose, repair or
service engine equipment.

11.1 Serviceable Parts

The serviceable items within the controller are:
1 The fuse on the front panel protects the electronics. Consulting your dealer
regarding changes to fuse ratings is recommended.
2 The Panel Lock located on the front of the door.
3 The clear see-through window.
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 47 of 57
 .

11.2 General
When troubleshooting problems, these general causes should be kept in mind:
1. Incorrect wiring of the unit.
2. Poor battery condition, battery not charged or poor battery connections.
3. Incorrectly connected or missing fly-back diodes on the engine electrics
which have inductive loads (starter motor, solenoids etc), which can cause
problems when they are switched off. These can cause resetting problems
for electronic components.
4. The RPM is used for a variety of purposes by the microprocessor program
apart from just displaying the engine speed. If the RPM is measured using
a signal from the alternator rather than a magnetic pickup then a faulty
alternator may be the likely cause, rather than a flat battery, in the event of
RPM read errors.
When an alarm or warning occurs during the operation of the engine, the engine will
be shutdown and a fault will be shown on the screen. The faults are shown in English,
though the following is a more detailed table of descriptions:

Fault Possible Cause Remedy

Oil Press. Low The oil pressure of the Check Oil Level and Oil
engine is low Pressure Sender
Engine Temp High Engine temperature has Check Water Level,
exceeded defined ‘safe’ Radiator Hoses & Leaks,
limit Oil Level.
Coolant Low / Engine coolant run out/low Check radiator coolant
Water Level Low level. Check water level
sensor
Alt Failure The Alternator fail signal Check alternator. Check
has been given to the K45-2 belts
Overspeed The engine has exceeded
the safe speed limit.
Zero/Low RPM The engine has stopped, or Check Speed Sensing
was traveling too slowly device
Maximum The PSI / KPa level was Check Pressure Sender
Pressure higher than the limit set via
Pressure Sender menu
Minimum Pressure The PSI / KPa level was Check Pressure Sender.
lower than the limit set via Check for blockages.
Pressure Sender menu
Failed Attempts The engine has failed to Check Fuel Level. Check
start several times, and Belts
exceeded the maximum
number of starting attempts.
Please note that the above is a guide to possible causes and remedies to faults only.
User discretion is advised. Only authorized and trained personnel can diagnose, repair
or service engine equipment.

11.3 LCD Display Faults

Display not visible Controller switched off Turn key to ON position
Battery voltage low Charge / Replace battery
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 48 of 57
 .

Controller is in sleep mode Press and hold any button

for a few seconds

Display is slow to refresh Ambient temperature is Relocate controller to

below range warmer area

Display is difficult to see Ambient temperature is Relocate controller to

above range cooler area
Controller is mounted in Mount controller away
direct sunlight from direct sunlight

On Power Up, the display Program not installed Contact authorized dealer
backlight is on with black correctly
bar across top line
Clock will not keep time RTC Battery requires Contact authorized dealer
once controller turned off replacement for replacement battery.
Startup power glitch Do a power reset. Remove
power for 3 or more
seconds then reconnect

11.4 Power Faults

Does not power on Battery leads not attached Ensure connections are
correctly secure and free of
corrosion
Fuse blown Check fuse condition
Low battery voltage Check battery condition
Battery leads incorrect Ensure terminal polarity
polarity adheres to wiring diagram

Controller loses power Fly-back diode incorrectly Ensure Fly-back diode

while starting engine fitted to fuel solenoid (or requirements are met as
missing) per wiring diagram
Fly-back diode incorrectly Ensure Fly-back diode
fitted to starter motor (or requirements are met as
missing) per wiring diagram
Low battery voltage Check battery condition
Power short due to Ensure all wiring adheres
incorrect wiring to wiring diagram
Alternator failure Alternator replacement
may be required
Fuel solenoid chatters Fly-back diode incorrectly Ensure Fly-back diode
fitted to fuel solenoid (or requirements are met as
missing) per wiring diagram
Low battery voltage Check battery condition
and condition of battery
leads

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 49 of 57
 .

11.5 Tachometer Faults

Engine is running, 0 rpm Alternator wiring incorrect Ensure wiring adheres to
shown wiring diagram
Alternator not excited Ensure wiring adheres to
wiring diagram
Alternator failure Alternator replacement
may be required
Controller has incorrect Contact authorized dealer
tachometer settings
No CAN BUS signal Ensure wiring adheres to
wiring diagram
Engine is running, Controller has incorrect Contact authorized dealer
incorrect rpm shown tachometer settings
Started motor does not Alternator wiring incorrect Ensure wiring adheres to
disengage wiring diagram
Alternator not excited Ensure wiring adheres to
wiring diagram
Alternator failure Alternator replacement
may be required
Controller has incorrect Contact authorized dealer
tachometer settings

RPM is incorrect only at Alternator failure Alternator replacement

certain engine speeds may be required
Alternator incompatibility Contact authorized dealer

Engine fault indicates over Reduction in engine load Check conditions of load
speed
Check throttle settings
Tachometer incorrectly set Contact authorized dealer

Engine fault indicates zero Fuel level low Ensure adequate fuel level
rpm
Alternator failure Alternator replacement
may be required
Alternator wiring incorrect Ensure wiring adheres to
wiring diagram

11.6 Engine Starting Faults

Starter motor does not Battery voltage low Check battery condition
crank
Starter motor wiring is Ensure wiring adheres to
incorrect wiring diagram

Engine cranks but does not Fuel solenoid not Ensure "Energize to Stop"
start operating correctly / "Energize to Run"
operation is set correctly
Ensure wiring adheres to

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 50 of 57
 .

wiring diagram
Ensure adequate fuel level
in tank

Fuel solenoid does not Fuel solenoid wiring Ensure wiring adheres to
operate incorrect wiring diagram
Fuel solenoid is incorrect Contact authorized dealer
type – ‘Energize to Stop’/
‘Energize to Run’

Engine runs briefly and is Sensor / Pressure / RPM See relevant

then automatically fault troubleshooting section
shutdown

11.7 Sensor Faults

Oil pressure fault is Oil level low Ensure oil level is
indicated adequate
Oil requires changing Check condition and age
of oil
Oil lines/sender has Verify oil flow is adequate
become blocked
Sender wiring is incorrect Ensure wiring adheres to
wiring diagram
Oil pressure sender is Contact authorized dealer
incorrect type

Coolant level fault is Coolant level low Ensure radiator coolant

indicated level is adequate
Coolant requires changing Check condition and age
of coolant
Sender wiring is incorrect Ensure wiring adheres to
wiring diagram
Sender is incorrectly Ensure sender is
mounted submerged at maximum
water level
Radiator is not grounding Check condition of
correctly radiator ground wire and
terminal
Sender is incorrect type Contact authorized dealer
Pump Temperature Pump temperature is above Check Sender
user Setpoint (sender type) Check Water in pump
Flow Switch Low Flow has been Check RPM is not too low.
detected Check for Blockages in
lines.
Check Sensor.

Alternator fault is Alternator wiring is Ensure wiring adheres to

indicated incorrect wiring diagram
Alternator failure Alternator replacement
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 51 of 57
 .

may be required

Sensor # fault is indicated The applicable sensor has Check condition for which
indicated a fault sensor provides protection

11.8 Pump Pressure Faults

Pressure reading is zero Sender wiring incorrect Ensure wiring adheres to
wiring diagram
Sender is incorrect type Contact authorized dealer
Sender settings incorrect Contact authorized dealer

Pressure is not displayed The controller does not Contact authorized dealer
measure pressure

Pressure is displayed as -- The pressure reading is Check pressure sender is

outside the applicable appropriate for application
range
Sender wiring incorrect Ensure wiring adheres to
wiring diagram
Sender is incorrect type Contact authorized dealer
Sender has incorrect Contact authorized dealer
settings

Engine shutdown due to Blocked pump and/or Check pump and pipes for
Max Pressure pipes blockage
Max pressure is incorrectly Adjust Max pressure
set setting in Set Pump
Pressure Sender Menu

Engine shutdown due to Pump head is not Check water level

Min Pressure sufficiently submerged
Min pressure is incorrectly Adjust Min pressure
set setting in Set Pump
Pressure Sender Menu

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 52 of 57
 .

12 Appendix A: Run Process Diagram

This Diagram shows the basic running process, from power on.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 53 of 57
 .

13 Appendix B: K45-2 Menu Map

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 54 of 57
 .

14 Appendix C: Float Setup Examples

Set in Start Parameters Input Type.

Input Type – “Start NO Stop NO” using 1 CR Float and 1 CF Float

Example shows both an Empty and Fill Application.
Note the orientation of the Start and Stop Floats in examples.

Input Type – “Start NO Stop NC” using 2 x CR Floats.

Example shows an Empty Application
Note the orientation of the Start and Stop Float.

Input Type – “Start NO Stop NC” using 2 x CF Floats.

Example shows a Fill Application
Note the orientation of the Start and Stop Float.

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 55 of 57
 .

Limited Warranty
Intention … This policy is written with the consumer in mind, therefore, the language is intended to be
simple and hopefully may assist consumers and companies in fully understanding the terms, their
obligations and the conditions of contract outlined within this warranty policy.

Names … Kensho P/L for the purposes of this warranty is the Original Equipment Manufacturer
(OEM) or ‘the manufacturer’. The ‘consumer’ means the end user, persons, company or group using
the Kensho product. The ‘original retail purchaser’ or ORP means (but not limited to) the
aftermarket re-seller, supplier or dealer of a particular brand of product/s. The ‘ORP’ also includes
Original Equipment Manufacturers and assemblers that have purchased any product from Kensho P/L.
The term ‘Stand-Alone Product’ means a Kensho product sold separately by the ORP and the ORP
has not fitted the Kensho product to their equipment or engines as a complete package.

What is covered … This warranty covers defects in manufacturing workmanship or materials

manufactured by Kensho P/L, with the exceptions as stated below.

Who is covered … This warranty and period of warranty strictly applies to the “original retail
purchaser”, that means the OEM, re-seller, supplier or dealer that “directly” bought the product from
the manufacturer.

How Long Coverage Lasts … This warranty runs for 24 months or 2000 engine operating hours
(whichever occurs first) from the day you purchase the product/s. Warranty periods in general may be
subject to change in future without notice. Please refer to the Manufacturer or Dealer in which the
product/s was purchased for any changes periodically.

What Kensho Will Do … KENSHO P/L at its discretion will repair any product proven to be
defective in materials or workmanship. In the event repair is not possible, replacement of the product
with a new or similar product/s and price, or refund of the full purchase price of the product, whichever
is deemed by the manufacturer appropriate to the original retail purchaser on a case by case basis.

ORP Obligations … Your obligations as the original retail purchaser are simple. The original retail
purchaser must consult Kensho from the suitability of the product to the environment and its intended
use. Fly-back diodes are a warranty requirement and correct wiring and installation of the product must
be followed as per the manufacturer’s requirements. Please also be aware that product was intended to
be installed by authorized agents with expert and technical knowledge and not for the average
consumer. You must therefore inform Kensho of each product sold as a ‘stand-alone product’ but not
fitted by you or your company as this warranty will not cover such claims. Also in the event of
complete product failure and on-site repairs are necessary Kensho must have the ‘first-right’ of call, in
other words, you must notify us prior to attempting repairs.

Consumer Obligations … The consumer must take care not to abuse, misuse, tamper with or damage
the product. Doing so will likely void this warranty but more importantly may cause loss of life or
limb. Please follow the instruction manuals on all your equipment and products carefully. Do not
modify, alter or repair this product under any circumstances. Please consult your approved and
authorized dealer or seller for technical issues. You are also obligated to be diligent during the
operation of your machinery.

What is not covered … This warranty does not cover equipment, components or engines supplied by
manufacturers’ other than Kensho P/L. Misused, Abused, Neglected, Damaged or Tampered with
product/s (whether accidental, intentional or incidental) are not eligible for any kind of warranty claim.
The product/s being used for a purpose or application not specifically designed for or intended by the
manufacturer. The product/s are not covered if electrically installed or wired incorrectly, contrary to the
manufacturer’s schematic and instructions or any unauthorized product/s modifications or alterations
not intended by the manufacturer. This warranty does not cover circumstances whereby the
manufacturer’s product is used in conjunction with or coupled to another manufacturer’s product
(whether electronic or otherwise) thus causing conflicts in operation, electrical interference or damage
to person and property. Excessive or incorrect power (voltages & amperages) to the product/s, contrary
to the manufacturer’s specifications, will void this warranty. The absence of FLY-BACK diodes in the
K45-2 – Dealer Manual Dealer Manual-20110826
YJ_2.0VP.doc
Page 56 of 57
 .

controllers’ electrical system will void warranty. This warranty will not cover damage to components
and circuit boards caused by excessive physical force applied by the user or original retail purchaser
when removing ‘replaceable relays’ or ‘pressing buttons’. This warranty does not cover disruption
caused by the manufacturer’s product/s to other electronic devices normal operation due to unshielded
radio/microwave frequencies or EMF interference. This warranty does not cover miscellaneous
expenses for removal, installation, service, towing or any down time, nor does it cover material, labor,
or additional parts required for replacement or repair of damages caused by abuse (including fire or
wreckage), misuse, neglect, if the product is defective by way of manufacturer, failure to follow
manufacturer’s operating, wiring and /or installation instructions. This warranty does not cover peeling,
fading or discoloration of decal/stickers, protective enclosure/s and the product in general caused by
extreme climates and temperatures, ‘Acts of God’, prolonged exposure to direct sunlight or frost,
chemicals or abrasives. Please consult your manual to determine the products acceptable operating
range, warning and recommendations. THE MANUFACTURER SHALL NOT BE LIABLE FOR
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION,
INDIRECT AND SPECIAL DAMAGES CAUSED BY AND RESULTING FROM DEFECTS IN
THE PRODUCT/S WHETHER CAUSED BY THE MANUFACTURER OR NOT. The replacement,
repair, time taken for repair or any other equitable remedy to the original retail purchaser will be solely
at the discretion of KENSHO P/L, including the cost for transit of faulty product/s from the
manufacturer to the original retail purchaser if the product is deemed to be a manufacturing fault. The
manufacturer will not be liable for loss or damage to product/s in transit between the original retail
purchaser and customer. Warranty claims are limited to the retail price paid for the product and may
not include the cost of labor or transport. The warranty period does not extend if the defective product/s
is repaired or replaced with new or is re-sold as second-hand goods by the consumer. This warranty
will not cover controllers sold as stand-alone units (in other words, sold without being fitted to a
specific engine) for reason that the product was intended to be installed by authorized agents with
expert knowledge. Repairs for product failure undertaken without the knowledge or consent of the
manufacturer will void warranty whether the repairs were undertaken by consumer or authorized agent.

How to get Service … The consumer may contact the OEM or dealer in the State or Country in which
the product was purchased. The dealer, reseller or OEM may proceed in making claim to the
manufacturer of the product. Warranty claims are for defect and manufacturing faults only and any
claims are only valid if;

• The warranty claim is made within the warranty period and before the allowable engine
operating hours,
• The customer makes a claim within 30 days of discovering the failure or fault,
• The “original retail purchaser” makes the warranty claim,
• Proof of purchase is supplied by way of serial number and company order/record,
• The product is not re-sold as second-hand good,
• The product fault is deemed by the manufacturer to be a manufacturing fault and not caused
by the customer.

How Law applies

This warranty gives you specific legal rights, and you may also have other rights which may vary from
State or Country.

THIS WARRANTY AND WARRANTY PERIODS ARE SUBJECT TO CHANGE WITHOUT

NOTICE. PLEASE CONSULT THE MANUFACTURER’S WEBSITE FOR CHANGES TO
WARRANTY TERMS AND CONDITIONS FOR YOUR PARTICULAR PRODUCT
THIS IS THE WHOLE AGREEMENT

K45-2 – Dealer Manual Dealer Manual-20110826

YJ_2.0VP.doc
Page 57 of 57