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DPI-2 Digital Pressure Indicator
Operating Instructions
DPI hand-held unit, version 2.04

Operating Instructions DPI hand-held unit, version 2.04
Introduction
This operating manual provides instructions on how to use this product

correctly, effectively and safely for the intended purpose. Please, do
read all instructions, notes on danger and warning, attentively. Please
follow all safety instructions and precautionary notes in order to avoid
damage to people or property during operation. LEUTERT can not be
held responsible for damage or injury resulting from improper product
use, incorrect operation or lack of maintenance.
This operating manual is directed mainly at technically trained personnel.

In case of doubt regarding safety or operational aspects, please do not
hesitate to contact LEUTERT for assistance. Should you notice a faulty
description or depiction or if you would like to suggest points for
improvement, we are looking forward to hearing from you.
Please keep the operating manual near the product to have it available if
needed. Make sure that the manual is protected from dirt and moisture.
Explanation of symbols:
DANGER
Immediate danger is possible causing severe injury or death if you do
not follow the instructions given.
WARNING
If you do not heed the warning, dangerous situations may occur leading
to severe injury or death.
CAUTION
Follow the instructions carefully, otherwise dangerous situations may
occur leading to injury or damage to property.
NOTICE
Please follow the recommendations and instructions for a correct and
flawless operation of the device or measuring system.
2 Friedrich Leutert GmbH & Co. KG

Contents
1 Product description....................................................................... 4
1.1 Application and function ..................................................... 4
1.2 Technical data...................................................................... 4
1.3 Scope of delivery.................................................................. 6
2 Fundamental safety advice and recommendations............................. 8
3 Design ....................................................................................... 10
4 Control and display elements ..................................................... 12

4.1 General information on operating the DPI hand-held unit..... 12
4.2 The function of the buttons of the DPI hand-held unit........ 12
4.3 Overview of the menu structure......................................... 13
5 Start of operation....................................................................... 14
5.1 Principal procedure for operating the DPI system................ 14
5.2 Charge battery................................................................... 15
5.3 Configure system............................................................... 16
5.3.1 Set time and date.................................................... 16
5.3.2 Select language...................................................... 18
5.3.3 Enter engine parameters......................................... 19
5.4 Delete data memory .......................................................... 22
5.5 Define measuring settings.................................................. 26
5.6 Install and adjust TDC sensor.............................................. 28
5.7 Install Crank Angle Encoder CAE........................................ 30
5.8 Installation of CAE/TDC sensor for welding of the bracket.... 32
5.9 Installing the incremental encoder...................................... 33
5.10 Installing the Alpha Lubricator connection kit...................... 35
6 Indication procedure................................................................... 40
6.1 Enter engine and cylinder number...................................... 41
6.2 Record measured data........................................................ 42
6.3 Check measuring settings and loading pressure..................44
6.4 Automatic recognition of alpha value................................. 46
6.5 Complete measuring series and remove pressure sensor...... 47
6.6 Display measuring results.................................................... 48
6.6.1 View data sets at the DPI........................................ 48
6.6.2 Transfer data sets to PC........................................... 48
6.7 Error messages................................................................... 49
6.8 Warnings........................................................................... 50
7 Maintenance.............................................................................. 51
7.1 Maintenance of the pressure sensor.................................... 51
7.2 Cleaning of the sensors...................................................... 51
7.3 Changing the battery pack................................................. 52
Appendix - Connecting rods.............................................................. 53
Friedrich Leutert GmbH & Co. KG 3

1 Product description
1.1 Application and function
The DPI (Digital Pressure Indicator) is a powerful and simple-to-use

electronic indication device. It serves to analyze 2- and 4-stroke large
diesel and gas engines in connection with the temperature compensated
pressure sensor, a specially developed measuring procedure allowing a
high level of precision of the measuring results.
An optional TDC sensor enables the display of the pressure curve in

relation to the top dead center of the crankshaft. When a fuel injection
sensor is used, the injection pressure is additionally measured. By using
a crank angle encoder (CAE) or incremental encoder, each pressure
value is measured as a function of the crankshaft angle.
While the measuring series is being recorded, the data may be read off
the LC display of the DPI hand-held unit. At the same time, the data
sets are put into memory and may be transferred to the PC via the
serial interface on completion of the measuring series. The data may be
depicted and administrated with the DPI software.
In order to connect the pressure sensor, the engine to be analyzed must

be equipped with a standard indication valve (Thompson connection). If
such a valve is not available, please contact LEUTERT.
The DPI system works independently of the mains voltage.
The system components of the DPI hand-held unit and pressure

sensor are adjusted to each other when they are delivered.
Readjustment will be necessary if the sensor unit or the DPI
hand-held unit is changed. LEUTERT will be pleased to give
advice.
1.2 Technical data
Pressure range : 0 – 250 bar
Standard connection : W 27 x 1/10”
Speed range : 35 – 800 rpm for 2-stroke engines

120 – 1400 rpm for 4-stroke engines
Sampling frequency : 7.0 kHz for 2-stroke engines

16.6 kHz for 4-stroke engines
Pressure resolution : 0.07 bar for pressure range 0 – 250 bar
Accuracy : < 0.5%
Fuel injection sensor : 0 – 2000 bar, 0 – 3000 bar

Memory capacity : 9 engines (32 data sets)
Battery capacity : 6 hrs
Degree of protection : IP 40 for hand-held unit
Battery charger
Input : 100 – 240 V AC, 50 – 60 Hz
Output : 12 V DC
Operating temperature range

Hand-held unit : 0 – 55 °C
Hand-held unit : 10 – 40 °C (during charge)
Battery charger : 0 – 55 °C
Pressure sensor : 0 – 350 °C
TDC sensor : 0 – 85 °C
CAE sensor : 0 – 80 °C
Fuel injection sensor : 0 – 125 °C
Incremental Encoder : 0 – 70 °C
Dimensions
Hand-held unit : 220 mm x 130 mm x 45 mm
Battery charger : 110 mm x 65 mm x 26 mm
Pressure sensor : Ø = 60 mm , L = 210 mm
TDC sensor : Ø = 12 mm , L = 85 mm
Fuel injection sensor : Ø = 62 mm , L = 190 mm
Incremental Encoder : Ø = 58 mm , L = 29.4 mm
Carrying case : 470 mm x 365 mm x 146 mm
Weight
Hand-held unit : 790 g
Battery charger : 180 g
Pressure sensor : 830 g
Carrying case : 6500 g incl. contents
CE labels
Basic EMC Emission Standard DIN EN 50081-1, Class B
Basic EMC Immunity Standard DIN EN 61000-4-1, susceptibility level
3
Safety regulations for electrical measuring, control and laboratory
instruments DIN EN 61010-1
Classification of degrees of protection provided by enclosures DIN
EN 60529
Pressure Equipment Directive 97/23/EC

1.3 Scope of delivery
Basic version
Carrying case with the components
– DPI hand-held unit with Removable Accumulator
– Shoulder strap
– Sensor unit for standard indication bore with 1 m connecting cable,
other lengths on request
– Calibration log
– Charger with Euro mains connector
– Box wrench for loosening the sensor
– Hex wrench to open up caps on each end of the DPI
– Serial interface cable for connecting the DPI hand-held unit to a PC
– DPI software on a CD, Operating instructions
Version with TDC sensor

In addition to the basic version, you can order TDC sensors in the
following variations:
– at fixed installation with 6 m – 25 m connecting cable
– with small junction box and connecting cable 6 m – 25 m with LEMO
connectors to connect the DPI hand-held unit and the junction box
– with fitting bushing and 6 m – 20 m connecting cable with LEMO
connectors for connection of DPI hand-held unit and TDC sensor
Version with TDC and CAE sensor (for 2-stroke engines only)
Optionally we offer the opportunity to order
– a TDC- and CAE-Sensor with 2 junction boxes, and 30 m of
connecting cable to link the two boxes. An additional 6 m – 20 m
cable with Amphenol connector is supplied to connect the DPI
hand-held unit to the junction box.
– Mounting support for TDC and CAE sensor
– Retainer for junction boxes
Design with incremental encoder (only for 2-stroke engines)

In addition to the basic design, we deliver on request
– Incremental encoder as a complete assembly kit for mounting on
Wärtsilä RT-flex engines without any mechanical modifications
Additional TDC or CAE sensors are not required when using the
incremental encoder.
Design with Alpha Lubricator connection kit (only for 2-stroke engines
with MAN Alpha Lubricator System)
In addition to the basic design, we deliver on request
– connection kit as a complete assembly kit for use of the incremental
encoder contained in the MAN Alpha Lubricator system
With the use of this connection kit, no additional incremental encoder
or TDC and CAE sensor are required.

Version with Fuel injection sensor

As a supplement to the variants with TDC or TDC/CAE sensor or
incremental encoder, you can order:
– Fuel injection sensor
– Safety valves corresponding to the amount of cylinders.
Accessories for all versions

– Magnets, Adhesive, Distance gauge
– Adapter cable USB - serial with driver software

2 Fundamental safety advice and recommendations
WARNING:
The DPI may only be employed by trained or qualified staff with

due care and observing the safety regulations for indication jobs
at large diesel and gas engines.
Please disconnect the pressure sensor from the indication

connection on completion of the measuring series in order to
prevent any overheating.
Please take suitable safety measures before touching the

pressure sensor if it is operational as its surface may reach
temperatures of more than 250 °C.
Cooling down the sensor with fluids is not permissible.
NEVER put the Pressure Sensor in the transport box when hot.
Wait until the sensor has cooled down.
Please protect the DPI hand-held unit and the charger from
moisture and observe the prescribed operating temperature (see
chapter 1.2).
Do not introduce any tools into the sensor bore.

Switch off the DPI on completion of a measuring series and

after data transfer to the PC, as the working time of the built-in
battery is limited to max. 6 hours.
When the red LED (low bat) is on, the remaining power lasts for
about 20 minutes. You should finish your measurement within
this time and recharge the battery with the AC adapter.
If the message CHARGE BATTERY appears, the remaining

capacity is insufficient to get valid measurement data.
The battery pack must be recharged at least every 9 months,

when not used.
Please ensure that the battery does not end in the domestic
waste for the sake of the environment. Please contact LEUTERT
regarding disposal.
The pressure sensor’s screw is sealed in order to avoid any

inappropriate repair or handling. Breaking the seal results in loss
of warranty.

3 Design
The electronic components of the DPI are located in a handy, portable

aluminum housing, see Fig. 1.
Connectors, see Fig. 3
Housing
LC display with background illumination,

4 x 16 characters for displaying the
measuring data and menu texts
Operating keys
red LED indicating low charge of battery
Fig. 1 - Front view of the DPI hand-held unit
The DPI system includes the pressure sensor depicted in Fig. 2, which
serves to determine the cylinder pressure in diesel and gas engines. It is
characterized by a high level of precision, rugged design and longevity.
Please refer to chapter 1.2 of this manual for the technical features.
Fig. 2 - Pressure sensor

Charge-indicating LEDs and connecting sockets are arranged at the

terminal side - see Fig 3.
Always switch the DPI off before connecting the plugs.
Contact between the sensors and the charger at the DPI is made by
means of a LEMO plug. When plugging the connections, please ensure
that the pertinent markings are aligned.
CAUTION: Because of identically sized plugs you may easily

mix up the plugs. In that case the connector’s pins may be
damaged. Therefore, be sure to only connect the plugs in the
corresponding bushing. The right combination may be identified
by the number of pins.
CAUTION: When disconnecting, pull on the knurled area of the

plug as the connectors have an interlocking mechanism. Do
not apply any rotational force to the plug as this might cause
damage.
5-pin connector for TDC sensor,

crank angle encoder (CAE),
incremental encoder or charger
4-pin connector for pressure sensor
3-pin connector for

fuel injection sensor
RS 232 as 9-pin Sub D

socket for PC connection
Yellow LED to indicate charging activity
Green LED to indicate connection and

status of the charging device
Fig. 3 - Connectors of DPI hand-held unit

4 Control and display elements
4.1 General information on operating the DPI hand-

held unit
You operate and configure the DPI using the four push buttons. Menu
texts and measuring data are displayed in the illuminated four-line LC
display.
The easy-to-read menu structure enables you to operate the measuring

system intuitively. Thanks to the menu-driven control, you will be able
to use the DPI effectively after only a short time.
4.2 The function of the buttons of the DPI hand-

held unit
Leutert DPI
Version 2.04 When the DPI is switched on, the Firmware version appears first, then
the main level of the menu depicted on the left. Please access the
required function from here using the 4 buttons.
Leutert DPI
measurement
measured data
A flashing cursor (_) marks the pertinent initial letter of the selected
settings menu item or a number.
The P button is the confirmation key which initiates the execution of

the selected function or completes a numerical entry.
In addition, you may use the P button to change over or to move some
input values:
Language (English/German), TDC sensor (1/0), averaging (1/0), filter
(2/1/0), stroke 2/4), show mip (0/1).
Using the  button you may move the cursor in a horizontal direction
for changing between functions within one line.
By pressing the  or  buttons you may move the cursor vertically

between the displayed functions or increase or decrease a selected
figure in predefined steps.

4.3 Overview of the menu structure
Leutert DPI start measuring save again save again

measurement cyl 1 alpha 180 r 108.8 rpm pinj 691.5 bar
measured data engine 1 pmax 137.9 bar mip 16.1 bar
settings main menu pdel 17.2 bar Pow 1884 kW
averaging [1] 0 FI sensor 0

filter [1] 1 CAE sensor 0
TDC sensor 1 show mip 1
FI sensor 0 back
engine 1
cylinder 12
alpha 180.0
back
engine 3
boost 2.3bar
back
time/date time [08:56:28] TDC signal off

German/English date [26-02-08] CAE signal off
configuration read config.
main menu back key
TDC signal engine 1

engine data number cyl 16
measurement 2/4 stroke 4
back back
engine
boost
cylinder
back
averaging [1] 0
filter [1] 1
TDC sensor 1
FI sensor 0
FI sensor 0
CAE sensor 0
show mip 1
back
view no 4 14:50 21-09

send engine 1 cyl 16
delete pmax 77 pdel 34
main menu r 746 mip 16.1
delete all
engine 1 send
back yes no
delete all delete data

delete eng. engine 1
delete indiv.
back

5 Start of operation
5.1 Principal procedure for operating the DPI system
1) Charge battery
You should charge the battery built into the DPI as a matter of course
when the charge message appears respect. after 6 months of disuse.
2) Configure system
You should prepare the measuring system for the specific operating
conditions, so that it will provide the correct results. This includes
entry of the engine parameters and setting date and time. Enter
these settings on the DPI hand-held unit where they will be put
into memory and will still be available when the unit is switched off
and back on again.
3) Delete data memory

We recommend that you delete the data sets put into memory in
the DPI completely before starting a new measuring series. The
configuration settings are not affected by this!
4) Preset measuring settings

Use the filter or average generation function to prevent unwanted
interference of the measuring results.
5) Installing optional sensors

Install and, if required, adjust the TDC sensor, crank angle encoder
(CAE), incremental encoder, or Alpha Lubricator connection kit.
Mount the sensors on the engine in accordance with the instructions.
6) Install pressure sensor

Install the pressure sensor at the indication bore of the diesel and
gas engine. At the beginning of the measurement, when the sensor
still is cool, do not tighten the sensor hard to the cylinder in order
to prevent it from getting stuck.
7) Install fuel injection sensor

Install the fuel injection sensor on the appropriate mounting hole
of the respective injection pump.
8) Connect sensors at the DPI hand-held unit and record

measuring data
Connect the sensors with the DPI hand-held unit and carry out the
measuring series. The DPI stores the measuring data of a maximum
of 32 cylinders. You have the option of following the measuring
procedure on the display of the DPI and, as necessary, of reacting
to error messages with corresponding measures.
9) Display measuring data

You may view stored data sets independently of the measuring
location on the display or transfer them to a PC, in order to carry
out a machine diagnosis with the assistance of the DPI software.

5.2 Charge battery
Charge the battery integrated into the DPI as a matter of course before
first use, always after the red LED (low bat) illuminates or the ‚charge
battery‘ message is displayed and after around 6 months of not being
used. Please use solely the charger which is part of the scope of delivery.
When put into storage the accumulator must be recharged at

least every 9 months. If the time of storage is longer than that,
you may need to charge the battery pack more than once. It is
also possible that the accumulator cannot be charged at all after
a long term storage.
You may recharge the battery how ever much residual capacity remains.
In order to avoid loss of capacity which occurs if the battery is always
charged after the same period of operation (Memory Effect), we
recommend to fully discharge the DPI from time to time.
1) Before starting the charging procedure, please ensure that the DPI
is switched off.
2) Connect the charger with the DPI hand-held unit using the plugs
3) Connect the charger to the mains voltage. The two LEDs inform
you about the charging procedure:
Green LED illuminated : The charger is connected.

Yellow LED illuminated : The charging is taking place.
Yellow LED off : The battery is charged 100 %.
The charger switches automatically into maintenance charging

mode as soon as maximum capacity of the battery has been
reached. Charging time may be as long as 2.75 hours depending
on residual capacity.
4) When charging has been completed or after max. 10 hours,

disconnect the charger from the mains.
5) Then disconnect the DPI from the charger. Pull on the beaded area
of the plug. Keep the charger in the carrying case.

5.3 Configure system

Please configure the measuring system when using it for the first
time and when parameters have been changed. The configured
values are maintained even when the DPI hand-held unit is
switched off.
5.3.1 Set time and date
The correct value for time and date is necessary to ensure exact
temporal allocation of the results gained during indicating.
Time and date are pre-set to CET (Central European Time). Due to the
inaccuracy of 1 min. per day, you should eliminate any differences
occurring. Also make this correction for changing between summer and
winter time.
The time is displayed in hours:minutes:seconds, the date is displayed in

the format Day - Month - Year.
1) Switch on the DPI hand-held unit by pressing the P button. The DPI
start menu appears on the display.
Leutert DPI
measurement
measured data
settings
2) Press  or  button, until the flashing cursor is in the ‚settings‘

line.
Leutert DPI
measurement
measured data
settings
3) Confirm the opening of the Settings menu using P. In the following

display the cursor will be seen in the ‚time/date‘ line.
time/date
German/English
configuration
main menu
4) Pressing the P button again will take you to the setting window for
time and date. The flashing cursor is the ‚time‘ line.
time [08:56:28]
date [26-02-08]
read config.
back
5) When the cursor is in the line to be processed, press P to activate

the programing. The cursor switches to the first changeable
number.

time [08:56:28]
date [26-02-08]
read config.
back 6) Carry out step 7 to change the number marked. If the figure marked
is correct, press P. The cursor thus jumps to the next adjustable
figure.
time [08:56:28]
date [26-02-08]
read config.
back
7) Make corrections to the figure selected in each case using  or .
time [08:59:28]
date [26-02-08]
read config.
back
8) Acknowledge your entry with P.
time [08:59:28]
date [26-02-08]
read config.
back
9) When you have worked through all figures of the time using P, the
cursor switches to the ‚back‘ line. If you notice wrong settings or
time [08:59:28] you would like to change the date you can move the cursor using
date [26-02-08]
read config.
 or  to the ‚time‘ or ‚date‘ line and repeat from step 5.
back
10) Initiate the ‚back‘ command using the P button to return to the
superior menu ‚settings‘.
time/date
German/English
configuration
main menu

5.3.2 Select language
Here you select whether the menu texts are to be displayed in English
or German language. Other languages are available as options.
1) Move to the ‚settings‘ menu, as described in steps 1 to 3 in

chapter 5.3.1.
time/date
German/English
configuration
main menu
2) Press button  or , until the flashing cursor is in the line ‚German/
English‘.
time/date
German/English
configuration
main manu
Uhrzeit/Datum 3) Use the P button to switch between the two languages. The menu
Englisch/Deutsch
Konfiguration texts always appear in the language currently activated. The cursor
Hauptebene marks the language currently not selected.
time/date
German/English
configuration
main menu
4) If you have the menu texts in the preferred language, move the
cursor using the  or  buttons for setting further items or switch
back to the main level.
time/date
German/English
configuration
main menu

5.3.3 Enter engine parameters
Enter the engine parameters once for every engine when it is put into
operation for the first time, or change engine characteristic values as
necessary. Make sure the entries are correct so that the DPI will supply
you with accurate measuring results.
Starting from version 3.24, the DPI software contains a

password-protected option for locking the engine parameters
and measurement settings. If these have already been entered in
the software and transmitted to the DPI hand held unit, it is not
possible to enter or change engine parameters on the DPI hand-
held unit with the lock enabled. If required, contact the person
responsible for password administration.
Input of individual parameters into the DPI hand-held unit

The following work steps adapt the measuring system to the diesel and
gas engines to be analyzed. You may enter and store the parameters of
a maximum of 9 engines in the DPI. These settings remain until replaced
by a new configuration.
Always use the correct engine number or name respectively

during indication so that the DPI can work with the pertinent
parameters.
Define the following engine data in the given ranges:
Engine number 1–9

Number of cylinders 1 – 24
Alpha (TDC offset) 0 – 360.0 in 0.5 °CA steps
Boost pressure 0 – 5.0 bar in 0.1 bar steps
Allocation of an engine number serves to differentiate between various

engines on board, as necessary, and enables clear allocation of the
measuring data to the engine. The alpha value indicates the TDC offset
of the respective cylinder in relation to the TDC of cylinder no. 1. The
following example shall illustrate this to you:
Engine with 9 cylinders in line, ignition interval 40 °CA
(Cylinder no.)
Firing order 1 9 2 7 4 5 6 3 8
Alpha 0 40 80 120 160 200 240 280 320
(TDC offset)
How to load all parameters from a computer

The definition of the engine parameter may be done on the PC. Then
they have to be transmitted to the DPI hand-held unit. Refer to chapter
4 in the DPI software manual.

1) Switch to the ‚settings‘ menu, as described in steps 1 to 3 in

time/date chapter 5.3.1.
German/English
configuration
main menu
2) Press buttons  or , until the flashing cursor is in the

‚configuration‘ line.
time/date
German/English
configuration
main menu
3) Press P in order to access the configuration menu.
TDC signal
engine data
measurement
back
4) Move the cursor into the ‚engine data‘ line using  or .
TDC signal NOTE: In the event that the ‚Engine data‘ menu is locked, you are
engine data
measurement not authorized to carry out the following steps.
back
5) You activate the allocated entry window with the P button.
engine
boost
cylinder
back 6) Press P when the cursor is in the line in which you would like to
configure the values. Begin with the ‚engine‘. Instead of the engine
number, the engine’s name may be displayed once the engines
data has been transferred from a PC.
engine 1
number cyl 1
2/4 stroke 4
back
7) Press button P again if you would like to change the displayed
engine number/name. The cursor switches to the changeable
figure.
engine 1
number cyl 1
2/4 stroke 4
back
8) Enter the desired engine number/name using the  or  button.
engine 3
number cyl 1
2/4 stroke 4
back
9) Acknowledge your entries with P. The cursor subsequently marks
the next line.

engine 3
number cyl 1
2/4 stroke 4
back
10) Press the P button in order to enter the number of cylinders of this
engine. The cursor jumps onto the corresponding figure.
engine 3
Anzahl Zyl 1
2/4 stroke 4
back
11) Select the right number of cylinders using the buttons  or .
engine 3
number cyl 12
2/4 stroke 4
back
12) Acknowledge your entry with P. The cursor now appears in the
next line for selection of the type of engine. Change between 2- or
4-stroke engine using the P key.
engine 3
number cyl 12
2/4 stroke 4
back
13) If the correct parameter is being displayed, move the cursor to the
‚back‘ line using button  or .
engine 3
number cyl 12
2/4 stroke 4
back
14) With P you switch back to the superior menu in which the line
‚boost‘ (pressure) is marked.
engine
boost
cylinder
back
For entering the characteristic values appearing there, you should use
the handling procedures from step 6 as a guide. Then switch to the
parameter ‚cylinder‘. Make sure the entries in the above areas are
precise.

5.4 Delete data memory
The DPI stores the measured values from a measuring series in the form
of data sets on the cylinder selected in each case.
If you want to record measured values beyond the 32 data sets, you
must replace data already stored, see chapter 6.2.
In order to avoid this, we recommend either completely deleting the

data memory or individually deleting the engine data before starting a
new measuring series.
The DPI hand-held unit is switched on. You see the start menu in the
Leutert DPI display window. Now follow the procedure described.
measurement
measured data
settings
1) Press button  or , until the flashing cursor is in the ‚measured
data‘ line.
Leutert DPI
measurement
measured data
settings
2) Press P to confirm that you want to switch to the processing menu
of the measured data. In the following display the cursor will be
seen in the ‚view‘ line.
view
send
delete
main menu
3) Move the cursor with  or  to the line ‚delete‘.
view
send
delete
main menu
4) Press P in order to access the following window with the deleting
options.
delete all
delete eng.
delete indiv.
back
5) Choose between the deleting functions using  or .

Delete data memory completely
delete all 6a) In order to delete all stored data sets, press P, when the cursor is in
delete eng.
delete indiv.
the line ‚delete all‘.
back
You can abort the deletion procedure by moving the cursor onto no
delete all with the  button and press P.
yes no
Acknowledge deleting with the P button when yes is marked.

Once you have started the process of deleting the data it cannot be
view stopped or interrupted.
send
delete
main menu
The DPI hand-held unit switches to a higher menu level afterwards.

Deleting data sets of an engine
delete all 6b) If you want to delete only data sets of one engine, move the cursor
delete eng.
delete indiv.
to ‚delete eng.‘ and press P.
back
delete data
engine 1
Pick the engine to be deleted by using the   keys.
delete data
engine 5
When the designated engine’s identification is shown on the

display, press P.
delete data
engine 5
yes no At this stage you can abort the process by moving the cursor with
the  key to no and confirm with P.
Otherwise just confirm the deletion of the engine by pressing P.

delete all Once you have started the process of deleting the data it cannot be
delete eng.
delete indiv. stopped or interrupted.
back
To delete data of other engines just follow the procedure described

above.
7b) With the command ‚back‘ you get back to the pertinent superior
menu level. Navigate to the required setting level using the buttons.

Delete individual data sets
delete all 6c) To delete certain data sets, press button P when the cursor is in the
delete eng.
delete indiv.
line ‚delete individually‘.
back
delete no 1
engine 1 cyl 1
time [08:56:28]
date [26-02-08]
Select the data set number to be deleted with  or . This function
is aborted by switching to ‚no. 0‘.
delete no 13
engine 1 cyl 1
time [08:57:35]
date [26-02-08]
Press P when the data set appears that you want to remove from
the memory. To delete further data sets individually, repeat step 6c.
delete all
delete eng.
delete indiv.
back
7c) With the command ‚back‘ you get back to the pertinent superior
menu level. Navigate to the required setting level using the buttons.

5.5 Define measuring settings

Starting from version 3.24, the DPI software contains a
password-protected option for locking the engine parameters
and measurement settings. If these have already been entered in
the software and transmitted to the DPI hand-held unit, it is not
possible to enter or change the measurement settings on the
DPI hand-held unit with the lock enabled. If required, contact
the person responsible for password administration.
Make use of the DPI’s ability to prevent interference affecting the

measuring results by selecting certain measuring settings. In this way
you get results that enable you to compare the measuring data of the
individual cylinders. For indication the DPI uses the pertinent currently
set measuring settings for all engines. These are stored until redefined.
Provided that you are authorized to do so, you may also define the
measurement settings in the DPI software on the PC and transmit them
to the DPI hand-held unit, see chapter 4 of the DPI software manual.
Access the menu depicted at the very bottom at the DPI to carry out the
following settings. In the meantime you are surely familiar enough with
the button operation that it is not necessary to mention every individual
single actuation of a button.
We recommend to use the values depicted in square brackets

as basic settings. Ensure identical measuring settings for later
measurements on the same engine in order to enable you to
carry out long-term investigations.
Leutert DPI Forming an average (Averaging 0 or 1)

measurement
measured data
Activate the averaging function in order to eliminate existing fluctuations
settings in combustion between the working cycles from the measuring results.
If averaging is activated, the DPI will additionally store the peak pressures
(ignition pressures) within these individual cycles.
time/date
German/English
configuration
When selecting this option, i.e. ‚averaging 1‘, the average is formed
main menu from the cylinder pressures of a defined number of working cycles. The
pre-setting of the DPI is averaging over 8 cycles, if required 1 value
between 2 and 16 is possible.
TDC signal
engine data
measurement
Select ‚averaging 0‘ if you want to acquire the non-averaged course of
back pressure.
If the expression ‚averaging‘ is marked, use the P button to switch

averaging [1] 0 between 0 or 1. When the required value is displayed switch to the next
filter [1] 1
TDC sensor 0
line using buttons  or  for selecting the filter.
FI sensor 0

Filtering (Filter 0, 1 or 2)
Use the filter function of the DPI to suppress the occurrence of
unwanted vibration, e.g. whistling vibrations. These are interfering
vibrations covering the measuring signal which can be caused by the
indicating channel.
2-stroke engine 4-stroke engine Smoothing

Filter 1 400 Hz 1.6 kHz slight
Filter 2 160 Hz 660 Hz strong
Choose between ‚filter 1‘ or ‚filter 2‘, to achieve a targeted band-

limit, i.e. smoothing of the measuring signal. Due to the strong
smoothing factor of Filter 2 it should only be used in exceptional cases.
Starting from version 3.24, the DPI software contains a filter

function. We recommend that you disable the filter function
in the DPI hand-held unit by setting it to ‚Filter 0‘. This will
enable detailed, unfiltered data to be stored. You can decide
subsequently in the DPI software, based on the curve shape,
whether you wish the data to be displayed with or without filter
on the monitor.
For switching between filters 0, 1 or 2 press button P when the cursor

is in the line ‚filter‘. When the required value is displayed, switch to
the line ‚TDC sensor‘ using button  or .
averaging [1] 0 TDC sensor (TDC sensor 0 or 1)

filter [1] 1
TDC sensor 1
If no TDC sensor is connected, you must enter the value 0, otherwise
FI sensor 0 an error message will appear on the display. In order to take the TDC
signal of an installed TDC sensor into consideration, select value 1. The
functions averaging and filtering work independently of whether a TDC
averaging [1] 0 sensor is activated or not.
filter [1] 1
TDC sensor 1
FI sensor 0 Use button P to choose between ‚TDC sensor‘ 0 and 1. Then switch to
line ‚back‘ using button  or  and quit the measuring settings with P.
FI sensor 1
CAE sensor 1
show mip 1
FI sensor, CAE sensor, show mip (0 or 1)
back For the FI sensor the same procedure as far the TDC sensor has to be
used. This setting is only available if the TDC sensor is enabled (set to 1),
because the CAE depends on the TDC sensor.
FI sensor 1 If the setting ‚show mip‘ is enabled (set to 1), the DPI calculates and
CAE sensor 1
show mip 1
displays the mean indicated pressure (mip) and the indicated power.
back
Incremental Encoder: LEUTERT or MAN (Alpha Lubricator connection kit)
If you are using an incremental encoder instead of the TDC or

CAE sensor, respectively, set both the TDC and the CAE sensor
to ‚1‘ in the menus shown on the left side.

5.6 Install and adjust TDC sensor
The use of a TDC sensor is optional. Due to the multitude of engines

available, we can only give you general installation advice for the TDC
sensor which you must adapt to the local conditions.
DANGER: Works on the TDC sensor may only be carried out

when the engine is at a standstill.
CAUTION: The installation may only be carried out by qualified

personnel. For installations and training courses, please contact
sales.maritime@leutert.com.
1) Determine a suitable place for mounting the sensor. Then adapt the
base holder, which is supplied on request with the TDC sensor, to
the place of installation or create you own holder in order to ensure
a stable and low-vibration fastening of the TDC sensor.
2) Mount the sensor holder and the sensor at the chosen place of
installation.
3) First place the magnet without adhesive on the flywheel in TDC

position (cylinder 1). Clean and degrease this area prior to this and
remove the protective coating if necessary.
NOTICE: Make sure that the side of the magnet marked red faces
the sensor.
Leutert DPI 4) Move the sensor until its distance to the magnet is 2 – 2.5 mm, see
measurement
measured data Fig 4. Use the distance gauge for this.
settings
5) Plug the TDC sensor cable into the pertinent connecting socket of
the DPI.
time/date
German/English
configuration 6) Switch on the DPI hand-held unit and switch to the configuration
main menu menu as described in the adjacent text.
TDC signal 7) Confirm the menu item ‚TDC signal‘ here. The message ‚TDC
engine data
measurement signal on‘ must appear on the display of the DPI as shown in the
back lower depiction.
8) Move the magnet against the rotational direction of the engine

TDC signal on until you see the message ‚TDC signal off‘ on the display of the
CAE signal off
DPI hand-held unit. Use the distance gauge to move the magnet if
key necessary.

9) Now move the magnet carefully back as far as necessary until ‚TDC
signal on‘ appears again on the display. Mark this position.
10) In the case of a surface mounting like in Fig. 4, fix the magnet
with adhesive exactly on the marked position. Please also read the
advice for using the adhesive supplied.
11) To implement a flush mounting as in Fig. 5, do the drilling in such a

way that the magnet projects at least 2.5 mm after being inserted.
Then readjust the distance of the magnet to the sensor.
TDC sensor
magnet
Fig. 4 - Surface mounting of the TDC sensor at different flywheel positions
Fig. 5 - Flush mounting of the magnet

5.7 Install Crank Angle Encoder CAE
The optional CAE provides a good reading of the angle. Therefore the
correlation to the pressure is much better and gives an accurate result.
Measurements with the CAE sensor are only reasonable when made in
combination with TDC sensor measurements.
Fig. 6 - Crank Angle Encoder
DANGER: Works on the crank angle encoder may only be carried

out when the engine is at a standstill.

When installing the Crank Angle Encoder (CAE) take care that the
flywheel teeth are not deformed by the turning gear. The best position
to install the Crank Angle Encoder is the outer edge of the flywheel,
because the gear mostly affects the middle of the teeth. Due to the
deformation, the distance between the CAE and the flywheel teeth
may decrease, and the CAE may be destroyed.
The Crank Angle Encoder has to be mounted such that the flat faces
of the CAE housing are parallel to the turning direction of the flywheel
(Fig. 6).
Alternatively, the CAE may be mounted pointing to one side of the

flywheel to prevent this problem. In both cases, the holder for the
CAE must be installed and the minimum distance must be determined
between holder and teeth that is required for one complete turn of
the engine. The CAE may be mounted at a minimum distance of one
millimeter to this minimal distance. This way, a possible later increase
in the play of the bearing would be taken into consideration. The
maximum distance should not exceed 2.5 millimeters.

The CAE and TDC sensor are linked to and inter-connected inside a
junction box. The linked data stream is transferred to another junction
box, which is equipped with a bushing for connecting to the DPI hand-
held unit (Fig. 7).
1 CAE 3
2 GND
3 +U 1
4 TDC 2
shield
DPI
Handheld
Unit
Upper junction box
CAE sensor
white : signal
green : minus power
brown : plus power
black : shield
CAE 1
GND 2
+U 3
TDC 4
shield
Lower junction box

TDC sensor
yellow : signal
green : minus power
brown : plus power
Fig. 7 - Junction-Boxes for TDC and CAE sensor

5.8 Installation of CAE and TDC sensor for welding

of the bracket
TO UPPER JUNCTION BOX
LOWER
JUNCTION
BOX
30
TDC
FLY WHEEL
CAE
ENGINE HOUSE
SENSORS FOR ENGINE WELDING THE BRACKET BEAM FOR ENGINE

TACHOMETER TACHOMETER
Fig. 8 – Installation of the CAE and TDC sensor for welding of the bracket

5.9 Installing the incremental encoder
The use of the incremental encoder is optional. It delivers up to 2048

pulses to the electronics system, thereby enabling a very precise
recording of the engine data, such as the position of the top dead
centre, or of the crankshaft angle. Therefore, no additional TDC sensor
and CAE sensor is required here.
The incremental encoder is delivered to you with a complete assembly

kit for mounting on Wärtsila RT-flex engines (see Fig. 9).
The sensor can be installed without having to carry out mechanical

modifications on the engine, such as e. g. drilling holes.
Fig. 9 – Incremental encoder incl. mounting elements
DANGER: Works on the incremental encoder may only be

carried out when the engine is at a standstill.

1) Turn engine with turning gear until no. 1 cylinder is at TDC.
2) Take off rear cover from RT-flex sensor by removing the four M12
screws.
3) Install the mounting plate for the torque support on the RT-flex
sensor housing using the three M12x60 screws, M12 spring washers
and spacers.
4) Attach torque support to incremental encoder by means of the M4

screw.
5) Connect the sensor cable of the incremental encoder to the lower

junction box. Make sure to pull the cable through the mounting/
spacer ring from inside before connecting it to the junction box.
6) Plug the DPI connecting cable into the pertinent connecting socket
of the DPI-2.

Leutert DPI 7) Switch on the DPI hand-held unit and switch to the configuration
measurement menu as described in the adjacent text.
measured data
settings
8) Now turn the incremental encoder by hand until ‚TDC signal on‘ is
shown in the display of the DPI handheld unit, using the red mark
time/date on the incremental encoder for orientation. This procedure may
German/English take some time and requires a steady hand.
configuration
main menu
9) When the correct position has been reached, slide the incremental
encoder over the 10 mm diameter shaft protruding from the RT-
TDC signal flex sensor.
engine data
measurement
back 10) Attach the torque support to the mounting plate using the M6
screw.
TDC signal on 11) Subsequently, readjust the incremental encoder, if required (see
CAE signal off step 8). To assist turning, you may insert an Allen key into one of
key the mounting bolts of the incremental encoder. Observe the display
of the DPI hand-held unit.
12) If the DPI handheld unit indicates ‚TDC signal on‘, as shown in the
lower display, tighten the two mounting bolts of the incremental
encoder. The incremental encoder is now fixed on the shaft (see
Fig. 10).
Fig. 10 – Installed incremental encoder
13) Reinstall the cover of the RT-flex sensor using the M12x60 screws
(see Fig. 11).
14) Install the upper junction box on the top platform of the engine.
Fig. 11 – Reinstalled cover of the RT-flex sensor

5.10 Installing the Alpha Lubricator connection kit
The use of the Leutert Alpha Lubricator connection kit (in the following
referred to as Leutert connection kit) is optional and suitable exclusively
for engines equipped with an MAN Alpha Lubricator System. It enables
the use of the incremental encoder already standard installed with the
MAN Alpha Lubricator without impairing its function. For this purpose,
neither an additional incremental encoder, nor TDC or CAE sensors are
required.
The Leutert connection kit contains a connection box with a fixed cable
connection to the MAN Alpha Lubricator Intermediate Box (in the fol-
lowing referred to as intermediate box) and a plug-in DPI connecting
cable (see Fig. 12).
For the installation of the Leutert connection kit, the intermediate box
must be provided with a bore to realize the electrical connection to the
Leutert connection box through the threaded cable gland included in
the delivery.
For this purpose, you need a power drill, a 20 mm step drill (or similar),
and open-jawed spanners with opening widths of 22 mm and 24 mm.
DPI connecting cable
Threaded cable gland

Lock-nut
Leutert connection box
Cable for connection

to the MAN Alpha
Lubricator Intermediate
Box
Fig. 12 – Leutert Alpha Lubricator connection kit
DANGER: Works on the Alpha Lubricator must only be carried

out when the engine is at a standstill.


1) Fasten the Leutert connection box by means of the mounting

bracket on the motor level of the cylinders. Place it in such a way
that the connected cables can easily reach each of the cylinders
during pressure measurement by means of the DPI handheld unit.
2) Lay the black connecting cable to the intermediate box. If required,

shorten the cable to the proper length. Allow for sufficient reserve
for cabling inside the intermediate box.
3) Open the MAN intermediate box (see Fig. 13), and measure the
voltage supply between the terminals „+E Volt” (red cable) and
„GND (0V)” (blue cable).
red: +E Volt
blue: GND (0 V)
purple: TDC inverted

white: CAE inverted
Fig. 13 – MAN Alpha Lubricator Intermediate Box
In the rare event that the voltage supply should be at 5 V, please

reconnect the three white signal cables in the Leutert connection
box from the lower right to the lower left clamping strip designated
„5 V” (see Fig. 14). In doing so, pay attention to the color coding of
the individual terminals.
Fig. 14 – Leutert connection box

CAUTION: If the 5 V input is used with a signal voltage of

10 – 30 V, the Leutert connection box may be damaged, and
the function of the Alpha Lubricator may be affected. If the
10 – 30 V input is used with a signal voltage of 5 V, this may
lead to failures of the DPI system because of a lack of TDC or
CAE signals, respectively! The function of the Alpha Lubricator
will not be affected in this case, however.
4) Disconnect the intermediate box from the power supply. This can
also be achieved by disconnecting the supply voltage „+E Volt”.
5) For the connection to the Leutert connection box, a threaded cable

gland must be installed on the intermediate box. For this purpose, a
hole with a diameter of 20 mm must be drilled on the right side.
Mark the position of the bore on the side. Please make sure that
there are no obstacles (e. g. printed circuit board, terminal strip)
within a radius of approximately 15 mm around the centre of the
bore and that there is enough space for tightening the lock-nut.
Loosen the screws of the printed circuit board in the intermediate

box and remove the board from the intermediate box together with
the connected cables.
Use the step drill to carefully drill a hole of Ø 20 mm through the

side of the intermediate box. Now fasten the threaded cable gland
included in the delivery by means of the lock-nut (see Fig. 15).
Fig. 15 – Fastening the threaded cable gland (here by means of an example on a

different box)

6) Insulate the previously routed fixed cable of the Leutert connection

box just far enough so that the outer insulation barely reaches into
the intermediate box.
Twist the shielding, and provide it with the heat-shrinkable tubing

included in the delivery.
Cut all wires to the appropriate length so that you can later easily
connect them in the intermediate box. We recommend the use of
wire end sleeves.
Now lead the cable through the threaded cable gland and tighten
the latter.
7) Screw the previously removed printed circuit board back in place in

the intermediate box.
Connect the cable ends 1, 2, and 4 (see labelling) of the fixed cable
connection of the Leutert connection box with the cables of the
incoming signals in the MAN Intermediate Box:
– Cable end no. 4 (TDC) to the purple cable (TDC signal, inverted)
– Cable end no. 1 (CAE) to the white cable (CAE signal, inverted)
– Cable end no. 2 (GND) directly to pins 2, 4, 6, and 8 on the
right clamping strip, or together with the blue cable to pin 4 on
the left clamping strip.
We recommend the use of wire end sleeves.
Use the crimp-type socket included in the delivery to connect the

previously twisted shielding of the fixed cable with the housing.
Fig. 16 – Fully connected MAN Alpha Lubricator Intermediate Box (similar

threaded cable gland)
8) Restore the power supply, close the intermediate box, and use the
DPI connecting cable to connect the TDC/CAE measuring channel
of the DPI handheld unit to the Leutert connection box.

Leutert DPI After having completed the installation steps described above, verify
measurement the signals of the MAN Alpha Lubricator as follows:
measured data
settings
1) Connect the TDC sensor to the Leutert connection box and to the
time/date DPI hand-held unit.
German/English
configuration
main menu 2) Switch on the DPI hand-held unit and switch to the configuration
menu as described in the adjacent text.
TDC signal 3) When turning the motor by means of the turning gear, the CAE
engine data display must change between ‚CAE Signal on‘ and ‚CAE Signal
measurement
back off‘. Depending on the speed or pulse number, this may be so
fast that it is only be perceived as a flicker. Only when the sensor
passes over the TDC (cylinder 1), the TDC display changes from ‚TDC
TDC signal off signal off‘ to ‚TDC signal on‘ for a short moment.
CAE signal off
key

6 Indication procedure
Install pressure sensor
CAUTION: Before installing the pressure sensor, clean the

relevant indication channel by fully opening the indicator
valve briefly while the engine is running in order to blow out
the channel. You thus avoid the sensor membrane being
contaminated or damaged.
Then fasten the pressure sensor at the indication bore of the engine.
When starting the measurements, tighten the initially cold sensor only
slightly in order to prevent it from seizing.
Measuring conditions
Before beginning the test series, check whether the TDC is configured
correctly (chapter 5.3), the data memory has been deleted (chapter 5.4)
and the measuring settings (chapter 5.5) are applicable.
To achieve comparable results, ensure that the load remains as stable

and the number of RPM of the engine as constant as possible during
the measuring. If, for example, a TDC sensor with activated averaging
is used when the load and RPM vary, this may cause additional angle
errors in the depiction of the TDC position.
Note down engine settings and operating conditions in order to

reproduce them for later measuring.
After you have connected the pressure sensor, switched on the DPI
hand-held unit and opened the indication valve completely, wait
for another 1.5 Minutes with a 4-stroke engine and 3 Minutes with
a 2-stroke engine respectively before recording the measured values
(once per engine), so that the sensor can work in its optimum operating
temperature range of 100 °C to 250 °C. Then carry out the measuring
series quickly to ensure identical conditions for all cylinders.
maesurement The menu on the left shows the waiting period until the optimum
engine1 cyl1
warm up phase
operating temperature of the sensor is reached.
>>>>
Do not switch off the DPI hand-held unit before completion of

the measurements, otherwise you would have to wait for the
preheating time of the pressure sensor again.

6.1 Enter engine and cylinder number

Enter engine and cylinder number
Leutert DPI Select the item (pressure) ‚measurement‘ in the DPI start menu and
measurement
measured data
confirm by pressing the P button.
settings
Switch to the line ‚engine‘ using the buttons  or . Press P to enter
the number of the engine to be investigated. You increase or reduce
start measuring the number with button  or . Acknowledge the selected engine
cyl 1 alpha 180
engine 1 number with P.
main menu
The DPI has an automatic cylinder switching function, i.e. measurement
is always carried out from cylinder 1 consecutively to the maximum
start measuring number of cylinders defined for the pertinent engine. Should you
cyl 1 alpha 180
engine 3
deviate from this procedure, enter the required number of cylinders
main menu explicitly prior to measuring.
To do this, press button  or , until the flashing cursor is under cyl.

start measuring Move to number of cylinders using button P and increase or reduce the
cyl 2 alpha 180
engine 3
figure with  or . Confirm the selected number of cylinders with P.
main menu
Now begin recording the measured data as described in the next

chapter. Please take into consideration that the data memory of the DPI
can include a maximum of 32 data sets.
Each data set contains
– Time and date

– Number of engine and cylinder
– Type of engine
– Type of filter
– Number of averaging
– Starting angle of the pressure curves with installed TDC sensor
– Boost pressure, manually entered value
– Engine Speed
– Course of cylinder pressure
– Peak pressure
– Differential pressure
– Mean indicated pressure
– Injection pressure process with installed fuel injection sensor
– Starting angle of the injection pressure curves
– Peak pressure fluctuations with active averaging
– Number of flywheel teeth with activated CAE sensor
Please note that the data set number is not always identical with
the cylinder number.

6.2 Record measured data
Initiate measuring and store measured data

Leutert DPI Begin the measuring series by selecting the item (pressure)
measurement ‚measurement‘ from the DPI start menu and confirm with button P.
measured data
settings
When the cursor is in the line ‘start measuring‘, press the P button
again to start the measuring series. On the display of the DPI appear, one
after the other, the messages ‚read in values‘, ‚ignition interval‘,
start measuring ‚rpm‘, ‚measurement‘ and ‚calculation‘ which will inform you of the
cyl 1 alpha 180
relevant internal processes.
engine 3
main menu
In the following display of measuring data you see the engine RPM ‚r‘,
the peak pressure (ignition pressure) ‚pmax‘ calculated from the pressure
curve and the differential pressure ‚pdel‘ resulting from the difference
save again between the pressure at the beginning of combustion and the peak
r 108.8 rpm
pressure. If the differential pressure cannot be determined clearly, ‚0.0
pmax 137.9 bar
pdel 17.2 bar bar‘ is displayed.
Now decide whether you would like to store the results thus determined
or would like to repeat the measurement:
save again
r 108.8 rpm
Press P to store when the term ‚save‘ is marked by the cursor.
pmax 137.9 bar
pdel 17.2 bar
In order to repeat the measurement, move the cursor with the  button
to repeat, acknowledge your selection using P and then store.
start measuring When you have stored the data set, you may continue the measurement
cyl 2 alpha 180
with the next cylinder. Repeat the procedure in each case with ‚start
engine 3
main menu measuring‘ until all cylinders have been measured.
If the system recognizes an error during the measuring

procedure, a corresponding message will appear on the display
of the DPI. Please follow the steps described in chapter 6.7 for
eliminating the malfunction.

Overwrite measured data

save again If the message ‚memory full‘ appears in the display when data is being
r 108.8 rpm stored this means the storage allocation has reached 32 data sets. You
pmax 137.9 bar
pdel 17.2 bar do not have to interrupt indication in every case, but it is possible to
overwrite existing older data by the new. Please pay attention to the
advice below.
save again
pinj 691.5 bar Scroll down with the  button to get additional information about
mip 16.1 bar
Pow 1884 kW the measurement. This information is only available if the options are
enabled.
memory full The command ‚replace‘ is marked by the cursor. Confirm with P if
you want to overwrite a data set. You also have the option to prevent
replace abort overwriting by selecting ‚abort‘. Switch to this term with the  button
and acknowledge with P. The most recent data is not stored.
replace no. 8 Select the data set number to be overwritten using  or  buttons
engine 1 cyl 2 and press P. This stores the last measured data under this number. You
time [09:53:26]
date [26-02-08] can abort the procedure by selecting ‚no 0‘, i.e. the most recent data is
not stored.
start measuring If you continue the indication at this point by means of ‚start
cyl 2 Alpha 180 measuring‘ the message ‚memory full‘ will appear again. Either
engine 1
main menu overwrite existing data sets again or start the measuring series from the
beginning, but delete the whole data memory beforehand.
Overwriting data sets involves the difficulty that data sets of the
same engine recorded at different dates are mixed. This causes
an untidy measuring series. It is always better to delete the
data memory completely or the individual engine data before
recording a new measuring series, refer to chapter 5.4.

6.3 Check measuring settings and loading pressure
Within the menu pressure measurement you also have the option of
changing the loading pressure of the engine independently of the
configuration of the engine parameters according to chapter 5.3.3.
Furthermore, you may alter the stored measuring settings for averaging
and filter functions, please also refer to chapter 5.5.
This procedure is particularly suitable for individual measurements.

We recommend that you do not carry out changes during the course
of a measuring series as you need identical measuring conditions for
comparable data.
Please consider the steps to be carried out in this chapter as a special

case within the operation of the DPI as they deviate from the system of
button assignment described so far.
Check measuring settings

As already mentioned, the DPI uses the last measuring settings entered
Leutert DPI for calculations. This means that changes already become effective
measurement
measured data when storing the next data set.
settings
1) The button P carries out the (pressure) ‚measurement‘.
start maesuring
cyl 1 alpha 180
engine 3
main menu 2) Use the  button to activate the menu for the measuring settings
when the cursor is in the first line under ‚start measuring‘.
averaging [1] 0
filter [1] 1
TDC sensor 0 3) Check the correctness of the displayed values. Follow chapter 5.5
FI sensor 0 to carry out changes. Then enter ‚back‘ to return to the previous
menu in order to start a measurement.
The current measuring settings remain even after the DPI has
been switched off.

Check loading pressure

Please note that alterations to the loading pressure cannot be
permanently stored in this menu, i.e. these changes are lost when the
DPI is switched off. Permanent alteration of the loading pressure is
Leutert DPI only possible in the menu settings by configuring the engine data as in
measurement
measured data
chapter 5.3.3.
settings
1) The P button starts the (pressure) ‚measurement‘.
start measuring
cyl 1 alpha 180
engine 3
main menu
2) Move the cursor with  or  to the line ‚engine‘.
start measuring
cyl 1 alpha 180
engine 3
main menu
3) Activate the menu for checking the loading pressure with the 
button.
engine 3
boost 2.3bar
4) Check the correctness of the set loading pressure. Correct the value
back as necessary and then enter ‚back‘ to return to the previous menu
to start measurement.
Changes to the loading pressure made within the menu

‚measuring‘ are lost when the DPI is switched off.

6.4 Automatic recognition of alpha value
If a TDC sensor has been connected, the DPI automatically determines

the TDC offset (alpha) of the cylinder currently being indicated during
the measuring procedure and compares it to the value configured
for this cylinder. In order to prevent incorrect measurements, the DPI
signals differences of more than 16° shaft with the message ‚wrong
alphavalue‘.
wrong alphavalue Please, decide whether you want to change the TDC offset or continue
180 CA check:
cylinder number measuring with the previous value:
change continue
If you want to continue measuring with the configured value move to
‚continue‘ with the  button and acknowledge with P.
engine 1
cylinder 12
alpha 180.0 To make corrections, press button P, when the command ‚change‘ is
back marked.
If the cursor is marking the word ‚alpha‘, press the P button in order to
start measuring be able to change the alpha value using  or . If the correct ignition
cyl 12 alpha 120
engine 1 interval has been set, terminate this menu with P and continue the
main menu measuring series. Please note that this alteration is lost when the system
is switched off.
If you want the alpha values, which were changed during the
measuring procedure, to be stored permanently, switch to
the configuration menu for the engine data after finishing the
indication without switching off the DPI. If you store the TDC
offset here, it will not be lost when the DPI hand-held unit is
switched off.
Supplementary explanations
With the defined trigger level of 30 % peak pressure and the correlated
crank angle of -25 °CA, the ignition interval related is determined. This
is a control function to verify the entered angles for the TDCs.
If the criteria is exceeded, the calculated angle will be displayed and

can be accepted or modified by the user. The maximum error of the
calculation may be ± 8 °CA. Please regard the measured apha values
only as an orientation.

6.5 Complete measuring series and remove pressure

sensor
Do not forget to switch off the DPI hand-held unit after every use to
relieve the battery. After 10 minutes of standby the DPI hand-held unit
turns off automatically.
Leave the DPI hand-held unit switched on if you wish to index

several engines in succession in order to avoid unnecessary
warm-up phases of the device.
CAUTION: After completion of the measuring series, remove

the pressure sensor from the indication bore in order to avoid
overheating. To do this use the box spanner supplied.
If the pressure sensor cannot be screwed off, open the indicator valve
for a short time in order to release combustion pressure. Be sure to close
valve immediately after removing the sensor. Afterwards the pressure
sensor can be unscrewed.
Observe the safety advice in chapter 2.
Pull the connecting cable out of the DPI hand-held unit and keep those
system components in the carrying case which are supposed to be
stored there.

6.6 Display measuring results
6.6.1 View data sets at the DPI
Even during the recording of measured values, some of the data

determined may be seen on the DPI display such as RPM, peak
and differential pressure. The complete data sets may be viewed
independently of the measuring location on the DPI hand-held unit on
Leutert DPI conclusion of the measuring series.
measurement
measured data
settings Switch on the DPI and move to the menu ‚measured data‘.
view Select the function ‚view‘.

send
delete
main menu
The data set number is marked by the cursor. Switch through all existing
data sets with the buttons  or  and view the stored measured
no 4 14:50 21-09 values:
engine 1 cyl 16
pmax 77 pdel 34
r 746 mip 16.1 – Data set number, time, date (day-month)
– Engine and cylinder number
– Peak pressure pmax [bar], differential pressure pdel [bar]
view – Engine speed r [RPM] , mean indicated pressure [bar]
send
delete
main menu
You may exit this menu at any data set number using the P button.
Please, switch off the DPI hand-held unit.
6.6.2 Transfer data sets to PC
Use the DPI software which is part of the system for analyzing and
interpreting the recorded course of cylinder pressure. To do so, it is
necessary to transfer the stored data sets to the PC.
Please see chapter 5 of the DPI software manual for the process of the
data communication and evaluation.

6.7 Error messages

As soon as the system detects a malfunction, an appropriate message
will be shown in the DPI display window. Press any key in order to
remove the message. Eliminate the malfunction according to the
instructions given below.
Cause:
no pressure
– The pressure sensor is not correctly connected or the indication
key valve is not open.
Recommended measure:
– Check the firm seat of the pressure sensor connector, its contacts
and the sensor cable. Control the indication valve.
Cause:
no TDC signal
– The TDC sensor is not properly connected or a non-connected TDC
key sensor is activated. The engine speed is too low (< 50 rpm).
– Check firm seat of the TDC connector, its contacts and the TDC
cable. Choose the correct option for the TDC sensor according
to chapter 5.5. Control correct mounting and setting of the TDC
sensor according to chapter 5.6.
CAE Sensor Cause:

no signal
– The Crank Angle Encoder (CAE) is not connected properly or non
key connected CAE is activated.
– Check firm seat of the TDC connector, its contacts, the cable and
the connections in the junction box. Deactivate the CAE if none
is available according to chapter 5.5. Check the mounting and
adjustment of the Crank Angle Encoder. Refer to chapter 5.7.
Cause:
– The battery capacity is exhausted.
recharge battery Recommended measure:
– Quit all measurement activity immediately and recharge the battery
according to chapter 5.2.
Cause:
no connection
– The connection between the DPI and the PC via the serial interface
key is disrupted.
– Check the connectors, cables and PC port settings as well as the
correct order according to chapter 6.6.2.
Cause:
storage error
– If this message is displayed when the DPI is switched on, the stored
key calibration data of the pressure sensor are incorrect.
– Contact LEUTERT for debugging.

6.8 Warnings
Warnings indicate that undesirable or faulty results may occur during
further use of the device. Press any key to remove the message, and
carry out the recommended measures.
wrong alphavalue Meaning:

180 CA check:
cylinder number
– The automatically measured TDC offset does not match the stored
change continue value.
Cause:
– The cylinder number selected at the DPI hand-held unit does not
match the measured cylinder.
– Correct the cylinder number manually at the DPI hand-held unit
and repeat the measurement.
Cause:
– The indication valve is not opened correctly and/or defective.
– Please ensure that the indicating valve is completely opened
and then continue the measurement. Check the valve after the
measurement and replace it if necessary.
Cause:
memory full
– The data memory is completely filled.
replace abort Recommended measure:
– Delete the data memory according to chapter 5.4 before starting
the measurement or overwrite existing data sets during the
measuring series according to chapter 6.2.
Cause:
no data
– There are no data stored under the chosen engine number.
key Recommended measure:
– Choose the correct engine number.
Cause:
menue locked
– The menu for changing the engine parameters or measurement
back settings, respectively, is locked. You are not authorized to change
the values previously transmitted to the DPI hand-held unit via the
DPI software (starting from version 3.24).
– The menu can only be enabled by means of a password via the DPI
software by the person responsible for measurements

7 Maintenance
7.1 Maintenance of the pressure sensor
The DPI hand-held unit is maintenance-free. Make sure that the device
and the pertaining pressure sensor are returned to the company Leutert
for control of the calibration data after approx. 100 operating hours or
after 3 years, respectively.
While the calibration settings are controlled at LEUTERT, the

pressure sensor will be cleaned simultaneously.
7.2 Cleaning of the sensors
Cleaning of the pressure sensor

Remove regularly any soot or carbon deposits from the pressure
sensor since they might interfere with the measuring operation. The
contamination rate depends on the indicated engine and its operating
conditions. The cleaning intervals given below should, thus, be
considered as a rough guide:
– after some 5 operating hours for a diesel engine running on heavy

fuel
– after some 30 operating hours for an diesel engine running on
diesel oil
When using the equipment on gas driven engines, cleaning is not

required.
No warranty claims will be accepted for damage or destruction of the

pressure sensor due to non-respect of the following safety instruction.
CAUTION:
– Before cleaning, allow the sensor to cool down to less than 50 °C.
– Use commercial cleaning agent.
– Do not introduce any tools into the sensor bore.
– Do not disassemble the sensor unit.
– Wear safety glasses when blowing out the sensor bore.
For cleaning the pressure sensor proceed as follows:
1) Fix the sensor unit in upright position, with the sensor access bore
pointing upwards.
2) Pour the cleaning liquid in a mixture ratio of 1:10 into the sensor
bore and allow to react for about 30 min. to 1 hour.
3) Remove the introduced cleaning agent by turning the device upside

down.

4) Afterwards, blow out the sensor bore by means of compressed air

(max. 4 bar).
5) Any remaining cleaning agent may be removed with clear water by

repeating steps 3 and 4.
If the sensor is heavily stained repeat the cleaning procedure.
Cleaning of the TDC sensor and the CAE

For a perfect operation, remove oil and dirt from the TDC sensor and
Crank Angle Encoder.
– Do not use any aggressive cleaning agents such as e. g. cleaner’s

naphtha.
DANGER: This work must be done only when the engine is

stopped!
7.3 Changing the battery pack

CAUTION: Switch off the DPI hand-held unit and disconnect the
charger before beginning the procedure.
When the battery pack needs to be changed or removed, follow the

steps below:
1) Unscrew the front-end lid by means of the provided hex wrench.

Afterwards pull out the battery pack (see Fig. 17).
2) Press the latch lock and pull the connection plug from the battery
pack (see Fig. 18).
Fig. 17 – Remove storage battery Fig. 18 – Pull connecting plug
To install the battery pack please follow the steps in reverse order.

Appendix - Connecting rods

Manufacturer Type Bore Stroke Con-rod
SULZER RLB66 660 1400 2220
RLA90 900 1900 3000
RLB90 900 1900 3000
RND68 680 1250 2300
RND68M 680 1250 2304
RND76 760 1550 2910
RND76M 760 1550 2430
RND90 900 1550 2880
RND90M 900 1550 2882
RTA48 480 1400 1100
RTA52U 520 1800 1980
RTA58 580 1700 2600
RTA58T 580 2416 2242
RTA58TB 580 2416 2242
RTA62U 620 2150 2360
RTA68TB 680 2720 2690
RTA72U 720 2500 2750
RTA76 760 2200 3250
RTA84 840 2400 2760
RTA84 840 2500 3450
RTA84M 840 2900 3480
RTA84T 840 3150 3300
RTA84C 840 2400 2760
RTA96C 960 2500 2880
MAN B&W K45GUC 450 900 1500
K62EF 620 1400 2590
K74EF 740 1600 2700
K80MCC 800 2300 2920
K90GB 900 2180 3280
K90GFCA 900 1800 2670
K90MC 900 2550 3505
K98MCC 980 2400 3090
L27/38 270 380 840
L35MC 350 1050 1260
L45 450
L50MC 500 1620 1950
L55GFCA 550 1380 1958
L60MC 600 1944 2305
L60MCE 600 1944 2041
L67GFCA 670 1700 2537
L70MC 700 2268 2730
L80GB 800 1950 2928
L80GFCA 800 1950 2928
L80MC 800 2592 3550
S35MC 350 1400 1600
S50MC 500 1910 2190
S60MC 600 2292 2628
S60MCC 600 2292 2460
S60MCC 600 2400 2460
S70MC 700 2674 2810
S70MCC 700 2674 2870
S80MC 800 3056 3550
MAK / Catterpillar M32 320 480 936
M453C 320 420 878
MU351 240 350 553
Deutz M628 280 240 504
Wärtsilä W38 380 475 1015

© Friedrich Leutert GmbH & Co. KG, Adendorf, 2008
This document including all of its parts is protected by copyright. Any

duplication or utilization outside of the copyright law is not permitted
without explicit permission from LEUTERT and may be subject to
prosecution. This applies in particular to duplications of any kind,
translations and incorporation into electronic systems.
– Original edition, manuals in other languages on request –
Subject to change without notice

Issued 3 April 2014

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DPI-2 Digital Pressure Indicator

DPI hand-held unit, version 2.04

This operating manual provides instructions on how to use this product

This operating manual is directed mainly at technically trained personnel.

2 Friedrich Leutert GmbH & Co. KG

2 Fundamental safety advice and recommendations............................. 8

4 Control and display elements ..................................................... 12

Appendix - Connecting rods.............................................................. 53

Friedrich Leutert GmbH & Co. KG 3

1.1 Application and function

The DPI (Digital Pressure Indicator) is a powerful and simple-to-use

An optional TDC sensor enables the display of the pressure curve in

In order to connect the pressure sensor, the engine to be analyzed must

The DPI system works independently of the mains voltage.

The system components of the DPI hand-held unit and pressure

1.2 Technical data

Pressure range : 0 – 250 bar

Standard connection : W 27 x 1/10”

Speed range : 35 – 800 rpm for 2-stroke engines

Sampling frequency : 7.0 kHz for 2-stroke engines

Pressure resolution : 0.07 bar for pressure range 0 – 250 bar

Accuracy : < 0.5%

Fuel injection sensor : 0 – 2000 bar, 0 – 3000 bar

4 Friedrich Leutert GmbH & Co. KG

Memory capacity : 9 engines (32 data sets)

Battery capacity : 6 hrs

Degree of protection : IP 40 for hand-held unit

Operating temperature range

Friedrich Leutert GmbH & Co. KG 5

1.3 Scope of delivery

Version with TDC sensor

Design with incremental encoder (only for 2-stroke engines)

6 Friedrich Leutert GmbH & Co. KG

Version with Fuel injection sensor

Accessories for all versions

Friedrich Leutert GmbH & Co. KG 7

2 Fundamental safety advice and recommendations

The DPI may only be employed by trained or qualified staff with

Please disconnect the pressure sensor from the indication

Please take suitable safety measures before touching the

Cooling down the sensor with fluids is not permissible.

Do not introduce any tools into the sensor bore.

8 Friedrich Leutert GmbH & Co. KG

Switch off the DPI on completion of a measuring series and

If the message CHARGE BATTERY appears, the remaining

The battery pack must be recharged at least every 9 months,

The pressure sensor’s screw is sealed in order to avoid any

Friedrich Leutert GmbH & Co. KG 9

The electronic components of the DPI are located in a handy, portable

Connectors, see Fig. 3

LC display with background illumination,

red LED indicating low charge of battery

Fig. 1 - Front view of the DPI hand-held unit

Fig. 2 - Pressure sensor

10 Friedrich Leutert GmbH & Co. KG

Charge-indicating LEDs and connecting sockets are arranged at the

Always switch the DPI off before connecting the plugs.

CAUTION: Because of identically sized plugs you may easily

CAUTION: When disconnecting, pull on the knurled area of the