Functional Description: Electronic Systems System Description Diasys®

Functional Description
Electronic systems
System description
DiaSys®
Version 2.60
E531920/05E
Printed in Germany
© 2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 General Provisions 5.6 Log files 80
5.7 To menus 85
1.1 Safety 4 5.8 Operating data 86
1.1.1 Important provisions for all products 4
5.9 Maintenance predictor 87
1.1.2 Personnel and organizational requirements 5
1.1.3 Safety regulations for startup and operation 6
1.1.4 Safety regulations for maintenance and repair 6 Extras
work 7
1.1.5 Fire prevention and environmental protection,
6.1 General functions in "Tools" 93
fluids and lubricants, auxiliary materials 10 6.2 Reset Functions 109
1.1.6 Standards for safety notices in the text 12 6.2.1 General information on reset functions 109
6.2.2 Resetting DOC and/or DPF 110
6.2.3 Resetting oxygen sensor 112
2 Introduction 6.2.4 Teaching valve limits 114
2.1 General information on the DiaSys program 13 6.3 Injector Functions 116
6.3.1 General information on injector functions 116
6.3.2 Injector replacement without IIG 118
3 First Steps 6.3.3 Injector replacement – with IIG 121
6.3.4 Injector test 125
3.1 Preparations 17
6.3.5 Injector shutdown 128
3.2 Device description 20
4 Functions 7 Program MEM
4.1 Overview 46 7.1 Prepare for BDM programming 130

4.2 “Available functions” overview for ECS-UNI 7.2 Programming mode 137
and ADEC-UNI 51
4.3 “Available functions” overview for 8 Templates
RCS/MCS/SAM 53
4.4 “Available functions” overview for CDS, 8.1 Templates 142
CDSCR-03/4/5 55
4.5 "Available functions" overview for MDEC- 9 Appendix A
ECU-C1, ECU-2, LMB, ECU-183, R082 58 9.1 Abbreviations 147
9.2 Conversion tables 148
5 DiaSys used with Governors 9.3 MTU contact persons/service partners 152
5.1 Measured data 60
5.2 Parameters 68 10 Appendix B
5.3 Injector code 71 10.1 List of Figures 153
5.4 Send changed data to control unit 72 10.2 List of Tables 155
5.5 Download control unit 74 10.3 Index 156
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1 General Provisions
1.1 Safety
1.1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
• Within the permissible operating parameters in accordance with the (→ product data)
• With fluids and lubricants approved by the manufacturer in accordance with the (→ Fluids and Lubri-
cants Specifications of the manufacturer)
• With spare parts approved by the manufacturer in accordance with the (→ applicable Spare Parts
Catalog)
• In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
• In compliance with all safety instructions and in adherence to all warning notices in this manual
• In accordance with the maintenance requirements over the entire service life of the product (→ Main-
tenance Schedule)
• In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
• With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
• By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation.The manufacturer will accept no liability for such damage.
Modifications or conversions
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Unauthorized modifications to the product compromise safety.

The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
4 | General Provisions | E531920/05E 2013 - 04

1.1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
• Training at the Training Center of the manufacturer
• Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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1.1.3 Safety regulations for startup and operation
Safety regulations for startup
Install the product correctly and carry out acceptance in accordance the manufacturer's specifications
before putting the product into service.
Before the product is put into operation for the first time, all official authorizations must be available
and commissioning preconditions met.
When putting the product into operation, always ensure
• that all maintenance and repair work has been completed;
• that all loose parts have been removed from rotating machine components;
• that no-one is present in the danger zone of rotating machine components.
Immediately after putting the product into operation, make sure that all control and display instruments
as well as the signaling and alarm systems work properly.
Safety regulations for equipment operation

The operator must be familiar with the control and display elements.
The operator must be familiar with the consequences of any operations performed.
During operation, the display instruments and monitoring units must be permanently observed with re-
gard to present operating status, violation of limit values and warning or alarm messages.
Malfunctions and emergency stop

The procedures for cases of emergency, in particular, emergency stop, must be practiced regularly.
The following steps must be taken if a malfunction of the system is recognized or reported by the sys-
tem:
• Inform supervisor(s) in charge,
• Analyze the message,
• If required, carry out emergency operations e.g. emergency stop.
Operation
The following conditions must be fulfilled before starting the product:
• Wear ear protection.
• Ensure that the engine room is well ventilated.
• Do not inhale the exhaust gases of the product.
• Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere.
• Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent.
• Protect battery terminals, generator terminals or cables against accidental contact.
Operation of electrical equipment

When electrical equipment is in operation, certain components of these appliances are electrically live.
Observe the safety instructions for these devices.
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1.1.4 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50°C before starting maintenance work (risk of explosion
of oil vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the engine room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation.
Carry out function checks on a product in operation only if expressly permitted to do so.
Secure the product against unintentional starting, e.g. with start interlock.
Attach "Do not operate" sign in the operating area or to control equipment.
Disconnect the battery. Lock circuit breakers.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
The following additional instructions apply to starters with beryllium copper pinion:
• Breathing protection of filter class P2 must be applied during maintenance work to avoid health haz-
ards caused by the beryllium-containing pinion. Do not blow out the interior of the flywheel housing
or the starter with compressed air. Clean the flywheel housing inside with a class H dust extraction
device as an additional measure.
Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
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Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop-
erly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.

Ensure particular cleanness during maintenance and repair work on the product. After completion of
maintenance and repair work, make sure that no loose objects are in/on the product (e.g. cloths and
cable ties)
Safety regulations after completion of maintenance and repair work

Before barring, make sure that nobody is standing in the danger zone of the product.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the product (in particular, the barring tool).
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when weld-
ing in its vicinity.
Before starting welding work:
• Switch off the power supply master switch.
• Disconnect the battery.
• Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.
Hydraulic installation and removal

Check the function and safe operating condition of tools and fixtures to be used. Use only the specified
devices for hydraulic removal/installation procedures.
Observe the max. permissible push-on pressure specified for the equipment.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
• Vent the hydraulic installation/removal tool, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
• For hydraulic installation, screw on the tool with the piston retracted.
• For hydraulic removal, screw on the tool with the piston extended.
For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into
shaft end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries

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Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear protective clothing and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity.Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.

Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged dur-
ing operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable binders to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a function check on completion of all repair work. In partic-
ular, check the function of the engine emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack
defective electronic components and assemblies in a suitable manner when dispatched for repair, i.e.
protected, in particular, against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
Laser equipment must be fitted with the protective devices necessary for safe operation according to
type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
• Laser devices of classes 1, 2 or 3A.
• Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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1.1.5 Fire prevention and environmental protection, fluids and lubricants, auxiliary
materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires – therefore al-
ways keep the product in a clean condition. Do not leave cloths soaking with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.
Noise
Noise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicating
danger are drowned.
Wear ear protectors in work areas with a sound pressure level in excess of 85dB (A).
Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents as well as the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer. Noncompliance with these guidelines will lead to forfeiture of the operating permit issued by
the emission monitoring authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they are subjected to
proper recycling procedures.
Auxiliary materials, fluids and lubricants

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The applicable version may be downloaded at: http://
www.mtu-online.com/mtu/mtu-valuecare/mtu-valueservice-Technische-Dokumentation.
Auxiliary materials, fluids and lubricants might be hazardous goods or toxic substances.When using flu-
ids, lubricants, auxiliary materials and other chemical substances, follow the safety instructions that ap-
ply to the product. Take special care when using hot, chilled or caustic materials. When using flamma-
ble materials, avoid contact with ignition sources and do not smoke.
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Used oil
Used oil contains harmful combustion residue.
Rub barrier cream into hands.
Wash hands after contact with used oil.

Lead
• Adopt suitable measures to avoid the formation of lead dust.
• Switch on extraction system.
• When working with lead or lead-containing compounds, avoid direct contact to the skin and do not
inhale lead vapors.
• Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
• Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of
containers, results in a risk of explosion.
• Wear goggles when blowing off components or blowing away chips.
• Forcing compressed air into thin-walled containers (e.g. containers made of tin, plastic and glass) for
drying purposes or to check for leaks, results in a risk of bursting.
• Pay special attention to the pressure level in the compressed air network or pressure vessel.
• Assemblies or products to be connected must either be designed for this pressure, or, if the permit-
ted pressure for the connecting elements is lower than the pressure required, a pressure reducing
valve and safety valve (set to permitted pressure) must form an intermediate connection.
• Hose couplings and connections must be securely attached.
• Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
• First shut off compressed air lines before compressed air equipment is disconnected from the supply
line, or before the equipment or tool is to be replaced.
• Carry out leak test in accordance with the specifications.
Paints and lacquers

• Observe the relevant safety data sheet for all materials.
• When carrying out painting work outside the spray stands provided with fume extraction systems,
ensure that the area is well ventilated. Make sure that neighboring work areas are not impaired.
• Avoid open flames in the vicinity.
• No smoking.
• Observe fire prevention regulations.
• Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
• Store liquid nitrogen only in small quantities and always in specified containers (without fixed cov-
ers).
• Avoid body contact (eyes, hands).
• Wear protective clothing, protective gloves, closed shoes and protective goggles.
• Make sure that working area is well ventilated.
• Avoid all knocks and jars to the containers, fixtures or workpieces.
Acids/alkaline solutions/urea solution (AdBlue, DEF)

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• When working with acids and alkaline solutions, wear face mask, gloves and protective clothing.
• Do not inhale vapors.
• If urea solution was swallowed, rinse mouth and drink plenty of water.
• If the solutions was spilled onto clothing, remove the affected clothing immediately.
• In case of skin contact, rinse parts of the body thoroughly with clean water.
• Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi-
ble.

1.1.6 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury.
• Remedial action
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury.
• Remedial action
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries.
• Remedial action
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage.
• Remedial action
• Additional product information
Safety notices
u This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
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2 Introduction
2.1 General information on the DiaSys program
Purpose
The DiaSys program is required in order to communicate with various MTU control units, RCS-5 remote
control systems and MCS-5 monitoring systems.
The main functions of the DiaSys program are:
• Data communication with the central database
• Adjustment of engine management parameters
• Data recorder function
Note: For the most part, this manual contains information concerning the use of DiaSys together with
control units. The functions described require a level 1B hardware key (service/distributor). Menu
screen functions are not described in this manual.
Neither the requirements of DiaSys software on the hardware (PC) nor the installation of this software
is described in this document.
Terms and definitions

Term Meaning
ADEC Advanced Diesel Engine control unit
This term is not used in this document; instead, the term “ECU-7, ECU-8 and
ECU-9” is always used
MDEC MTU Diesel Engine Controller
This term is not used in this document; instead, the term “ECU-4” is always
used
Online mode The serial or the CAN interface of the PC is connected to the control unit and
the data connection to the control unit is established.
Refer to the illustration below (online mode)
Offline mode 1. The control unit is not connected to the serial or CAN interface of the PC.
The data connection to the control unit has been disconnected (office mode).
Refer to the illustration below (offline mode)
2. The control unit is connected to the serial or CAN interface of the PC. The
data connection to the control unit has been disconnected (programming
mode).
Functional software (FSW) Control unit operating system software.
Without FSW on the control unit, DiaSys can not switch to online mode.
Engine parameter set (MPS) These are operating parameters of the engine management control unit.
Local database Files or databases that are stored locally on the PC for an engine number.
The data may be intended for the control unit or for the central database.
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Central database For each engine number, the data (FSW and MPS) is stored centrally in a da-
tabase in Friedrichshafen, Germany. Also synonymous with: control unit data-
base.
CCS Compatibility Check System
Is used for checking the interdependencies between objects (software
and/or hardware) and to display object features.
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Online mode
Figure 1: Dialog box showing online data connection
Offline mode
Figure 2: Dialog box showing offline data connection
Hardware key
The hardware key
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• contains a range of owner-specific information (refer to chapter “Hardware Key Info”).

• is valid for a specific period. Three months before the hardware key expires, the operator receives a
reminder each time DiaSys is started.
Setting the CAN hardware used

To be able to connect the ECU-7, the DiaSys program must be told which IXXAT CAN adapter is being
used. This is normally done once in “Start | Settings | Control panel | IXXAT Interfaces”. There, the
adapter must be selected and the “Default HW” button clicked.
If DiaSys does not detect the adapter then the process must be repeated.
14 | Introduction | E531920/05E 2013 - 04

Key combinations
Key combina- Action Explanation
tion
Ctrl + Alt + P Displays the prop- Additional information depending on the active window.
erties window
Ctrl + P Print The active window is printed - if possible.
Ctrl + B Binary display In the single parameter window, parameters with the unit “digit”
can be displayed as binary values.
Ctrl + G Go to In the single parameter window, you can search for a certain pa-
rameter number.
Ctrl + Shift + A Prepare to export In the offline Y(t) display, measured values can be exported to a
the measured val- file in csv format.
ues For a more detailed explanation, see below.
F3 Restart recorder If you press the F3 key during a recording, then the previous re-
cording is automatically saved using a default name (current date)
together with a sequential number and a new measured data re-
cording sequence is started.
Explanation re Ctrl + Shift + A:

Ctrl + Shift + A opens the following window from the offline Y(t) screen:
Figure 3: Export window (CSV file)
Ctrl + Shift + S stores the values of the current cursor. On moving the cursor and repressing Ctrl + Shift
+ S, the next value is recorded. Ctrl + Shift + O ends the measurement and stores it via a file selection
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dialog box.
Note:
• If the key combinations are already otherwise assigned by the system then these combinations have
no effect within DiaSys.
Program Info
When the program is started the following window appears.
It shows the version number, copyright details and the date and time.
E531920/05E 2013 - 04 | Introduction | 15

Figure 4: Program Info window
After the "OK" button is pressed, a general safety notice appears drawing the operator's attention to
the dangers of incorrect operation and programming of the connected devices.
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Figure 5: Safety notice

Clicking “OK” takes you to the next program window. Clicking “Cancel” exits the program.
16 | Introduction | E531920/05E 2013 - 04

3 First Steps
3.1 Preparations
Starting the program
To start DiaSys successfully, the following operations are always required:
Starting the program ...
• Select user group
• Select device type
• Open device description or create new one
To work in online mode...
• Establish connection to the control unit (“connect”)
To work in offline mode...
• Establish connection to the control unit (“disconnect”)
User group
Selection of user group (activity group). Depending on the authoriozation level of the hardware key in-
serted, the number of selectable user groups may be greater or smaller. The functions offered by Dia-
Sys depend on the user group selected.
The description below refers to the functions that are available when the user group "Customer Service"
is selected. There are only a limited number of functions available in the user group "Customer".
Figure 6: User group

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Selecting device type

Selection of device type. This window is only activated if “No standard device type” is selected in the
Options window.
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Figure 7: Selecting device
The small " "buttons display pictures of the device or system concerned to facilitate identification.
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Figure 8: Selecting device – device view
18 | First Steps | E531920/05E 2013 - 04

The picture disappears as soon as the mouse is moved off the picture or the "ESC" key on the computer
keyboard is pressed.
Note:
• depending on the device type, different functions may be available in DiaSys.
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3.2 Device description
Enables you to select between Create, Open and Edit device description. Opening a device description
is a prerequisite for working with DiaSys in order to be able to use the functions described in the sec-
tion “Using DiaSys with engine management control units”.
For engine management control units ECU-1, ECU-4, ECU-7, ECU-8, ECU-9, ECU-183 and CDS/CR, the
settings are stored in the central database. From there they can be downloaded to the local database
on the computer using a modem or through the MTU network connection (LAN) and then onto the con-
trol unit. If parameters are changed on the control unit, then the changed data record must be saved
back to the central database so that the current status of the control unit remains up to date. The func-
tion “Establish connection to central database” is provided for data communication for the purpose.
The “Options” button provides the facility for selecting the language (German or English) for DiaSys and
making other settings.
Figure 9: Device description

The function selection options shown in the “Device description” window can vary depending on the
control unit connected.
Functions in DEVICE DESCRIPTION with Level E E E E E E C C R
1B hardware key, depending on control unit C C C C C C D D 0
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U U U U S U S S 8
- - - - - - / / 2
7, 4 2 1 U 1 C C
8 N 8 R
9 I 3
Create new device description X X X X X X X X X
Open device description X X X X X X X X X
Edit device description X X X X X X X X X
Establish connection to central database X X — X — X X — —
20 | First Steps | E531920/05E 2013 - 04

Functions in DEVICE DESCRIPTION with Level E E E E E E C C R
1B hardware key, depending on control unit C C C C C C D D 0
U U U U S U S S 8
- - - - - - / / 2
7, 4 2 1 U 1 C C
8 N 8 R
9 I 3
Transfer data using files X X — X — X X — —
Edit engine data in local database X X — X — X — — —
Data in local database — — — — — — X — —
Retrieve “ECU7info” from central database X — — — — — — — —
Options X X X X X X X X X
X = Function available
- = Function not available
Create new device description

Creating a new device description means assigning one or more engine numbers to a certain job num-
ber. The DiaSys program will then create folders in which the data will be stored.
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Figure 10: Creating a new device description

After you click the “New” button, the following window (see illustration) for entering an engine number
appears.
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Figure 11: Entering engine number
Note:
• Every job number must be linked to at least one engine number.
The “Available functions” window can only be accessed via this function and the “Open device descrip-
tion” function (see section “Using DiaSys with engine management control units”).
Open device description

Opening a device description means using a device description created previously.
The “Available functions” window can only be accessed via this function and the “Create new device
description” function (see section “Using DiaSys with engine management control units”).
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Figure 12: Opening a device description
22 | First Steps | E531920/05E 2013 - 04

Edit device description
Shows the available order numbers. The “Delete” function deletes all of the data for the selected job
number or the selected system name.
Figure 13: Selecting device description

After clicking on the “Delete” button, the following confirmation prompt will appear:
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Figure 14: Selecting device description – with dialog box
Note:
• This will delete an entire job (i.e. the complete plant) including all of the data transferred from the
control unit to the PC.
To remove individual engine numbers, proceed as follows. Engine parameter records in the local data-
base will not be removed.
After the “Edit” button is pressed, the following window appears:
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Figure 15: Editing device description
In this window you can either create or delete a new engine number within a job.
After the “OK” button is pressed, the window will close.
Establish connection to central database

Notes:
• Only available for engine management control units ECU-1, ECU-4, ECU-7, ECU-8, ECU-9, EIM,
ECU-183 and CDS/CR.
• CDS/CR is described in the next section.
After a connection has been established to the central database (either through a modem or the MTU
network (LAN)), engine data records that are in the local database can be transferred back to the cen-
tral database. Furthermore, engine data records can be copied from the central database to the local
database. The engine number clearly identifies the corresponding data records.
Notes:
• The connection to the central database cannot be interrupted. If an error occurs, it can take up to 2
minutes for the DiaSys program to respond to user input again.
• If a connection is established via a modem, the PC must not be connected to a local PC network
• In contrast with a LAN connection, when using a modem the user must connect to the central data-
base manually via the MTU IT Service Directory.
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Note – ECU-7, ECU-8, ECU-9 and EIM only:

• As soon as a connection with the central database is established and device type “ECU-7, ECU-8,
ECU-9, EIM” is selected, the latest version of the file “ECU7info” is automatically transferred to the
PC if necessary.
Important: every time a connection with the central database is established, the actions performed on
device ECU-7/ECU-8/ECU-9 and the actions "Download control unit" and "Delete control unit and
download new data" on device EIM are reported to the central database. Only the actions are reported,
the transfer of data - as usual - must be initiated by the user.
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Figure 16: Transfer parameter set to central database
There are two different types of data record in the local database:
Data record Contents of the data record
For control unit This is the data that originates from the central database and is intended for
(data for control unit) the control unit.
Actual data This is always where the current control unit data is stored. Every change to
(data from control unit) the control unit is recorded. When uploading a data record back to the cen-
tral database, it always is the “Actual data” that is transferred and then de-
leted from the local database.
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Figure 17: Retrieve parameter set from central database
There can be two data records per engine number in the central database:
Data record Contents of the data record
Modernized data (specified Modernization data is stored here.
data)
Last actual data from con- The “actual data last uploaded" is the data read from the control unit. It will
trol unit (actual data last up- only match the current actual data record for the control unit if it has been
loaded) consistently synchronized with the central database.
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Figure 18: Schematic diagram of data management
1 Central database 4 Actual data last uploaded 7 Local database
2 Engine parameter set 5 Actual data (data from 8 Engine management con-
(MPS) + Functional soft- control unit) trol unit
ware (FSW) 6 For control unit (data for
3 Specified data control unit)
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Transfer parameter set to central database
Figure 19: Transferring parameter set to central database

When uploading to the central database, multiple engine data records can be uploaded. Select the rele-
vant checkbox in the “Transfer” box for the engine number concerned.
The “Next” button takes you directly to the “Retrieve parameter set from central database” window.
Only the actual data from the control unit can be transferred to the central database. Clicking on the
“Transfer” button starts the data transfer.
Notes:
• When using a modem the user must connect to the central database via the MTU IT Service Directo-
ry. DiaSys will then be started and the data exchange can be prepared with the “Establish connection
to central database” function.
• If an engine data record is transferred via modem or LAN to the central database, it will be automati-
cally deleted from the local database after the transfer is completed.
• The function “Transfer data using files” does not delete the engine data record from the local data-
base when using the optionh “Export data”. After successful transfer of data, the user must manually
delete the data using the function “Edit engine data in local database”.
See also:
• The section “Establish connection to central database”
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• The section “Retrieve parameter set from central database”

• The section “Transfer data using files”
• The section “Edit engine data in local database”
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Retrieve parameter set from central database
Figure 20: Retrieving parameter set from central database

When retrieving a parameter set from the central database the engine number must be entered. Fur-
thermore, it must be stated whether “Modernized data” or “Last actual data from control unit” should
be retrieved.
The “Next” button takes you to the next window (see next illustration).
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Figure 21: Information on parameter set
This contains more information on the parameter set for the engine number entered.
After the “Retrieve data” button is pressed, data transfer from the central database to the local data-
base on the computer starts.
If the selected data record is not available, the “Retrieve data” button is disabled.
Note: the FSW is also transferred if required.
See also:
• The section “Transfer parameter set to central database”
• The section “Delete engine data from local database”
Establish connection to central database (for CDS/CR control units only)

Note: this section only relates to the CDS/CR control unit.
Step 1: Display of the number of data records that must be transferred to the central database (transfer
back of data).
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Figure 22: No entries in database server
Step 2: Automatic transfer of data to the central database.

Step 3: Window for entering CDS/CR software numbers which are to be transferred from the central
database to the PC (to the local database).
Note:
• Only those users whose hardware key is authorized for this function at MTU can copy software from
the central database to the PC. Error message: “You do not have authorization to download function-
al software from the central database!”
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Figure 23: Programming CDS/CR control unit
32 | First Steps | E531920/05E 2013 - 04

Transfer data using files
Note: Only available for engine management control units ECU-1, ECU-4, ECU-7, ECU-8, ECU-9, EIM,
ECU-183 and CDS/CR.
If data cannot be directly transferred using a modem or LAN then the engine data records can be trans-
ferred using files. These files can be imported into another computer and then transferred via LAN or
modem from that computer to the central database (the opposite direction is also possible).
Figure 24: Transferring data on storage medium
Export data
After the “Export files” button is pressed, the following window will appear.
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Figure 25: Database server export prompt
If the target folder specified in this window is not empty, the following window appears after you click
the "Yes" button:
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Figure 26: Delete contents confirmation

Once you have confirmed that export should start, the following window appears:
34 | First Steps | E531920/05E 2013 - 04
Figure 27: Transfer data using files – Settings
Option Procedure
Export to file This is for specifying the name of the file (user-definable), to which the
data is to be saved. A default name is automatically suggested.
Direction of data transfer This is for specifying whether “Data for the central database” or “Data for
control unit” is to be transferred.
Type of data compression This determines whether one large file is to be created and saved to a
storage medium or if the data is to be distributed over several disks. That
involves generating several small files which can then be manually copied
to disks.
After the “Next” button is pressed, the following window appears (except for CDS/CR):
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Figure 28: Exporting engine data record
You must specify which data (i.e. for which engine numbers) is to be exported. Clicking the relevant
checkboxes in the “Export” column either selects or deselects the data.
Once all required engine numbers have been selected, export is started by clicking the “Export” button.
After the transfer is successfully completed, the following window appears:
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Figure 29: Database server – export successful
Import data
Before data can be imported the file must be unpacked. This file will unpack itself. First copy it to any
folder on the interactive device (e.g. C:\TEMP).
Double-clicking the file (e.g. in WINDOWS™ Explorer) opens the following window:
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Figure 30: DIASYS – File extraction
Clicking the “Next >” button unpacks the file and automatically copies the data to the correct folder.
Now the actual import can be started.
After the “Import data” button is pressed (see illustration “Selection window for exporting or importing
files” in the section “Transfer data using files”), the following window will appear:
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Figure 31: Database server import prompt
You can only answer “Yes” to this question if the file has already been unpacked as described earlier.
The following window will appear:
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Figure 32: Importing engine data record
E531920/05E 2013 - 04 | First Steps | 39

Here you must specify which data (i.e. for which engine numbers) is to be imported. Clicking the rele-
vant checkboxes in the “Import” column either selects or deselects the data.
Note: For ECU-7, ECU-8, ECU-9, EIM and CDS/CR this window does not appear because all available
engine data records are always imported.
Once all required engine numbers have been selected, transfer is started by clicking the “Import” but-
ton. After the transfer is successfully completed, the following window appears:
Figure 33: Database server – import successful

Note: For CDS/CR, only data intended for the central database can be exported or imported.
Edit engine data in local database

Note: Only available for engine management control units ECU-1, ECU-4, ECU-7, ECU-8, ECU-9, EIM and
ECU-183.
Shows the available engine numbers. The “Delete” function deletes the engine data records from the
local database. The engine numbers selected in the “Delete” box will be deleted.
Note:
• Data records will be automatically deleted when transferring data using a modem or LAN. There is no
automatic deletion when transferring data using files.
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Figure 34: Editing engine data in local database
See also:
• The section “Transfer parameter set to central database”
• The section “Retrieve parameter set from central database”
Clicking the relevant checkboxes in the “Delete” column either selects or deselects the data.
As soon as at least one engine number is selected for deletion the “Delete” button is enabled.
Data in the local database

Note: Only available for CDS/CR control units.
The number of CDS/CR engine data records in the local database is shown.
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Figure 35: No entries in database server
Retrieve “ECU7info” from central database

Note: Only available for engine management control units ECU-7, ECU-8, ECU-9 and EIM.
Either a connection to the central database must be established or the PC must be connected to the
MTU LAN.
When the button is clicked: the program checks whether the “ECU7info” in the central database is
more recent than on the PC. If a more recent version is available, it is immediately copied to the PC and
used in future.
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Options
Figure 36: Settings

1 Selection of data to be log- 3 Setting the default path 5 Button for language selec-
ged 4 Button for viewing the file tion
2 Setting the default device “Log.txt” 6 Button for restoring de-
type fault settings
1. “What is logged”
The actions/messages logged in the file "log.txt" depend on the logging level. The file "log.txt" is a text
file designed as a revolving log.
2. “Default device type”

If a “default device type” is specified, that control unit (or RCS/MCS) is taken to be the default device
type when the program is started, i.e the device does not have to be manually selected. The “Select
device type" window is skipped.
3. "Default path"
For various functions (e.g. Restore maintenance predictor) you can specify a path other than the disk
drive (A:) to/from an external data medium.
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4. “Show file 'Log.txt'"

Allows you to view the log file "log.txt".
5. “Select language"
Sets the active language for the DiaSys user interface:
Select the checkbox “Switch language for DiaSys”.
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Figure 37: Selecting language
Click “OK” button.
Confirm message by clicking “OK”.
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After restarting DiaSys, the desired language (German or English) can be selected:
6. "Default settings"
The following settings are restored to their default values:
Default value
What is logged “Error"
Default device type “- No default device type -”
Default path “A:\”
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E531920/05E 2013 - 04 | First Steps | 45

4 Functions
4.1 Overview
The window illustrated below shows which functions are available for a selected control unit., (The win-
dows may be differrent depending on the control unit connected and the user group selected).
Figure 40: "Available functions" window showing details for ECU 9

Online only
MDEC-C2
ECU 7
ECU 8
ECU 9
EIM
Function
Establish connection to control unit x x x x x

Start measured data recording x x x x x
Stop measured data recording x x x x x
Analyze measured data x x x x
Export measured data x x x x
Injector code x
Edit single parameters x x x x x
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Edit 2D parameters x x x x x
Edit 3D parameters x x x x x
Send changed data to control unit x x x x x x
To menus x x x x x
Exit x x x x x
SPECIAL PARAMETERS
Edit input/output settings x x x
46 | Functions | E531920/05E 2013 - 04

Online only
MDEC-C2
ECU 7
ECU 8
ECU 9
EIM
Function
Edit alarm parameters x x x

Edit protection/monitoring parameters x x x
LOG FILES
Error log file x x x x x
Delete error log file x x x x x x
Export error log file x x x x x
Modification log file x x x x x
Parameter modified by x x x x x
Device ID x
TOOLS
Export to Excel file x x x x x
Hardware key Info x x x x x
Show engine number x x x x x
Retrieve all parameter settings x x x x x x
Show trip data x x x x
Show xxx alive signal x x x x
Show alive signal x x x x x
Select language x x x x
Read out Leakage map x x (2) x (2)
Show CCS tree x x x x
Show hardware CCS x x x x
Show CCS info x x x x
Show CCS info x x x x
Show data record number x x x x
Export MCR overshoots x x (2) x x (2)
Data record from local database ... x x x x
Settings x x x x x
Read Autolearn charge-air pressure x x (2)
Read Autolearn BOI x x (2)
Reset oil priming pump x x
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Crash recorder (on TOOLS menu)

Show status x x x x
Cancel interlock x x x x
Upload from control unit and export x x x x
Reset functions (on TOOLS menu)

AGN reset function (DOC and DPF) (5) x (x) (2)
Oxygen sensor reset function x x
E531920/05E 2013 - 04 | Functions | 47

Online only
MDEC-C2
ECU 7
ECU 8
ECU 9
EIM
Function
Hardware replacement (on TOOLS menu)

Delete control unit and download new data (offline) x x x x x
Set to storage mode (offline) x x x x
Injector functions (on TOOLS menu)

Injector shutdown x x x (2) x (2)
Injektortest x x x (2) x x (2)
Show analysis x x (2) x x (2)
Injector replacement (4) x x (2) x x (2)
ENGINE HISTORY DATA

Load profile x x x
Load change counter x x x
Turbocharger switching counter x x
Start counter x x x
Revolution counter x x x
Show PV recorder x x
Save data for analysis x x x
Save as x x x
MAINTENANCE PREDICTOR
Load profile x
Save data for analysis x
Save all (for restore) x
Restore... x x
Central database data transfer

Establish connection to central database x x x x x
Transfer data using files x x x x x
Edit engine data in local database x x x x x
Retrieve xxx info from central database x x x x
UPDATE CONTROL UNIT (MODERNIZATION)

Update control unit (modernization) x x x x x x
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Emergency mode (3) x x x x x
EMU-8
Programming mode Gas Gas x
Establish connection to central database Gas Gas x
Transfer data using files Gas Gas x
Edit engine data in local database Gas Gas x
OPTIONS
48 | Functions | E531920/05E 2013 - 04

Online only
MDEC-C2
ECU 7
ECU 8
ECU 9
EIM
Function
What is logged x x x x x
Default device type x x x x x
Default path x x x x x
Show file 'log.txt' x x x x x
Select language x x x x x
Default settings x x x x x
Standard hardware x x x x x
Additional functions on 'menu-based' user interface

Parameters/Compare parameters x x x x x
Show/Online x x x x x x
File/Database utilities/Compress/Repair database x x x x x
(1)
Parameters/Modification log and Log file/Delete log x x x x x
file
Programs x x x x x
Engine number must be available on control unit x x x x x
* These functions are only available if a control unit is connected and online.
(1): Only available if device description has been closed.
(2): Not for gas engines.
(3): Button only available when required.
(4): ECU-7 without IIG, ECU-8 with/without IIG, ECU-9 with IIG.
(5): (x) can be switched on/off in registry.
Gas: only available for gas engines
Establish connection to control unit

The connected control unit is addressed via a serial interface (CAN).
Pressing the "OK" button establishes an online connection with the control unit (online mode).
If there is no connection or if the connection has been disconnected by clicking the “Disconnect” but-
ton, only an offline analysis (e.g. from measured data) is possible (offline mode).
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Figure 41: Establish connection to control unit
E531920/05E 2013 - 04 | Functions | 49

Note
• Until the “Establish connection to control unit” button has been clicked and confirmed by pressing
“OK”, most of the buttons in the “Available functions” will be grayed out and therefore not available.
Tools
The "Tools" window is of particular importance in terms of control unit configuration. The functions ac-
cessible from that window enable extensive control unit analyses and settings to be performed.
Figure 42: "Tools" window showing details for ECU 9

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50 | Functions | E531920/05E 2013 - 04

4.2 “Available functions” overview for ECS-UNI and ADEC-UNI
The window illustrated below shows which functions are available for the two versions of the UNI sys-
tem. (The windows may be different depending on the control unit connected and the user group select-
ed).
Online only*
ECS-UNI
ADEC-UNI
Function
Establish connection to control unit x x

Start measured data recording x x x
Stop measured data recording x x x
Analyze measured data x x
Export measured data x x
Edit single parameters x x
Edit 2D parameters x x
Edit 3D parameters x x
Download edited parameters to control unit x x x
To menus x x
Exit x x
LOG FILES
Error log file x x
Delete error log file x x x
Export error log file x x
Modification log file x x
Parameter modified by x x
Device ID x x
TOOLS
Export to Excel file x x
Import Excel file x x -
Hardware key info x x
Show engine number x x
Show data record number x x
Retrieve all parameter settings x x x
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Transfer parameter settings to backup device x x x

Settings x x
Confirm scheduled maintenance x x x
Load profile x x
TBO parameters x x
Confirm load-dependent maintenance x x x
E531920/05E 2013 - 04 | Functions | 51

Online only*
ECS-UNI
ADEC-UNI
Function
Service life matrix x x

Move scheduled dates x x x
Sched. maintenance dates x x
Save data for analysis x x
Maintenance date tolerances x x x
Load-dependent maintenance dates x x
Save all (for restore) x x x
Modify K factor x x x
Restore... x x x
New Ti matrix x x x

Establish connection to central database x x
Transfer data using files
Edit data in local database x x
DOWNLOAD CONTROL UNIT PROGRAM MEM

Delete control unit and download new data (offline) x x
Program LOP MEM x x
OPTIONS
What is logged x x
Default device type x x
Default path x x
Show file 'log.txt' x x
Select language x x
Default settings x x
Standard hardware x x

Parameters/Compare parameters x x
Show/Online x x x
File/Database utilities/Compress/Repair database (1) x x
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Parameters/Modification log and Log file/Delete log file x x

Programs x x
Engine number on control unit must not be 0 x
* These functions are only available if a UNI system is connected and online.
52 | Functions | E531920/05E 2013 - 04

4.3 “Available functions” overview for RCS/MCS/SAM
The window illustrated below shows which functions are available for the following systems/devices.
• Remote Control System RCS
• MCS monitoring systems
• Service and Application Module (SAM)
(The windows may be different depending on the system connected and the user group selected).
Functions Online only* RCS/MCS/SAM
Read device description x
Establish connection to CAN bus x x
Select device x
Start measured data recording x x
Stop measured data recording x x
Analyze measured data x
Export measured data x
Edit single parameters x
Edit 2D parameters x
Edit 3D parameters x
Compare modified parameters x
To menus x
BDM log x
Exit x
LOG FILES
Modification log file x
Data record information x
Information on device description x
TOOLS
Export to Excel file x
Hardware key info x
Show alive signal x x
Export 'Initial <-> Original value' x
Select language x
Settings x
OPTIONS
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What is logged x
Default device type x
Default path x
Settings x
Show file 'log.txt' x
Select language x
Default settings x
E531920/05E 2013 - 04 | Functions | 53

Functions Online only* RCS/MCS/SAM
Standard hardware x
Rail diag x
Programming mode x x
Prepare for BDM programming x
Show system faults x x

Parameters/Compare parameters x
Show/Online x x
File/Database utilities/Compress/Repair database (1) x
Parameters/Modification log and Log file/Delete log file x
Programs x
(1) Only available if device description has been closed.

* These functions are only available if the system/device is connected and online.
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54 | Functions | E531920/05E 2013 - 04

4.4 “Available functions” overview for CDS, CDSCR-03/4/5
The window illustrated below shows which functions are available for the various versions of the CDS.
(The windows may be different depending on the CDS connected and the user group selected).
Online only*
CDS/C
CDS/CR-01
CDS/CR-02
CDS/CR-03
CDS/CR-04
CDS/CR-05
Function
Establish connection to control unit x x x x x x

Start measured data recording x x x x x x x
Stop measured data recording x x x x x x x
Analyze measured data x x x x x x
Export measured data x x x x x x
Edit single parameters x x x x x x
Edit 2D parameters x x x x x x
Edit 3D parameters x x x x x x
Send changed data to control unit x x x x x x x
Update control unit (modernization) x x x x
To menus x x x x x x
Exit x x x x x x
LOG FILES
Error log file x(1) x x x x x
Delete error log (2) x x(1)
Export error log file x(1) x x x x x
Modification log file x x x x x x
Parameter modified by x x x x x x
EOL parameter modified by - - - x x x
Show device information - - - x x x
Device ID x x x x x x
TOOLS
Export to Excel file x x x x x x
Import Excel file x x x x x x x
Hardware key info x x x x x x
Show engine number x x x
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Calibrate actuator x x
Injection volume calibration x x x x
Torque calibration x x
Test actuator x x
Edit engine configuration x x x x
Data provision x x x x
Show load profile (3) x x x x x x
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Online only*
CDS/C
CDS/CR-01
CDS/CR-02
CDS/CR-03
CDS/CR-04
CDS/CR-05
Function
Retrieve all parameter settings x x x x x x x

Settings x x x x x x
Crash recorder (on TOOLS menu) (1)

Upload from control unit and export x x x x
Delete crash recorder x x x x
Reset functions (on TOOLS menu) - - -

Load profile and operating hours (and overall x x - - - - -
fuel consumption)
Cyclical switch x x - - - - -
Fault memory x - - - - -
EDM x - - -
Heating flange cycle counter x x
Operating hours, starboard glowplugs x x x
Operating hours, port-side glowplugs x x x
Operating hours, heaters 1/2/3 starboard, and x x
4/5/6 port
Operating hours, heaters 1/2/3 port, and x x
4/5/6 starboard
Cold-start counter x x x
Injector functions (on TOOLS menu)

Injector functions x x x x
Show analysis x x x

Establish connection to central database x x x x x
Transfer data using files x x x x x
Data in local database x x x x x
OPTIONS
What is logged x x x x x x
Default device type x x x x x x
Default path x x x x x x
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Show file 'log.txt' x x x x x x

Select language x x x x x x
Default settings x x x x x x
Standard hardware x x x x x x
Additional functions on 'menu-based' user inter-

face
Parameters/Compare parameters x x x x x x
56 | Functions | E531920/05E 2013 - 04

Online only*
CDS/C
CDS/CR-01
CDS/CR-02
CDS/CR-03
CDS/CR-04
CDS/CR-05
Function
Show/Online x x x x x x x
File/Database utilities/Compress/Repair data- x x x x x x
base (4)
Parameters/Modification log and Log file/ x x x x x x
Delete log file
Programs x x x x x x
(1) Not supported by all control units.

(2) For CDS/CR under Tools/Delete functions.
(3) Other functions available by right-clicking: Update data; Upload from data medium; Export data as
Excel file.
* These functions are only available if the CDS is connected and online.
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4.5 "Available functions" overview for MDEC-ECU-C1, ECU-2, LMB,
ECU-183, R082
The window illustrated below shows which functions are available for the control units concerned.
(The windows may be different depending on the control unit connected and the user group selected).
Online only
ECU-LMB
MDEC-ECU-C1
ECU-2
ECU-183
R082
Function
Establish connection to control unit x x x x x

Start measured data recording x x x x x x
Stop measured data recording x x x x x x
Analyze measured data x x x x x
Export measured data x x x x x
Edit single parameters x x x x
Edit 2D parameters x x x x
Edit 3D parameters x x x x
Send changed data to control unit x x x x x
Transfer new FSW to device x
To menus x x - x x
Exit x x x x x
LOG FILES
Error log file x - x x
Delete error log file x x - - x
Export error log file x - - x
Modification log file x x x x
Parameter modified by - - x(1) x(1)
Device ID x x x x
TOOLS
Export to Excel file x x x x -
Import Excel file x x x x x -
Hardware key info x x x x x
Retrieve all parameter settings x x x x x -
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Show engine number - x x -

Show data record number - - x -
Settings x x x x x
Hardware replacement (on TOOLS menu)

Delete control unit and download new data (offline) x
Load profile x
58 | Functions | E531920/05E 2013 - 04

Online only
ECU-LMB
MDEC-ECU-C1
ECU-2
ECU-183
R082
Function
Save data for analysis x

Save all (for restore) x x
Restore... x x

Establish connection to central database x x
Transfer data using files x x
Edit engine data in local database x x
UPDATE CONTROL UNIT (MODERNIZATION)

Update control unit (modernization) x x x
Emergency mode (3) x
OPTIONS
What is logged x x x x x
Default device type x x x x x
Default path x x x x x
Show 'log.txt' file x x x x x
Select language x x x x x
Default settings x x x x x
Standard hardware x x x x x

Parameters/Compare parameters x x x -
Show/Online x x x x x
File/Database utilities/Compress/Repair database x x x x
(2)
Parameters/Modification log and Log file/Delete log x x x -
file
Programs x x x x
(1) Not supported by all control units.

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* These functions are only available if the CDS is connected and online.
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5 DiaSys used with Governors
5.1 Measured data
Starting measured data recording
Starting measured data recording without a trigger
Selected measured data can be read from the control unit. It can be stored and represented graphically.
Note: The following window only appears when it is activated (as required).
If no trigger has been defined or no trigger is to be selected then “No” should be selected in the follow-
ing window.
Figure 43: Triggered start

This window is used for selecting measuring points.
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60 | DiaSys used with Governors | E531920/05E 2013 - 04

Figure 44: Selecting measurement points for data recording
Option Description
Available meas- Available measuring points of the selected device
uring points
Group of meas- Here you can select a stored group
uring points
For data record- List of the selected measuring points
ing
Select all measuring points
Selects the marked measuring points in “Available measuring points”. Single measuring
points can also be selected by double-clicking.
To select multiple measuring points, drag your mouse over the desired measuring points
or click on several measuring points while keeping the Ctrl key pressed.
Deselects the marked measuring points in “data recording”. Single measuring points can
also be deselected by double-clicking.
To deselect multiple measuring points, drag your mouse over the desired measuring
points or click on several measuring points while keeping the Ctrl key pressed.
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Deselect all measuring points
Templates
Export Available templates for selecting the measuring points to be recorded can be copied into
a non project-specific template database from within the current device description.
They can then be copied to another device description via “Import” at a later date.
Import Templates for the selection of the measuring points to be recorded can be copied to the
current device description from the non project-specific template database.
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Templates
New Creates a new template name within the current device description. The measuring
points must then be subsequently selected and the “Save” option executed.
Delete Templates can be deleted from the current device description.
Save A selected template can be changed. The changes are applied by selecting “Save”.
Save as If no template is selected then “Save as” creates a new template.
If a template is selected, then “Save as” saves an existing or opened and modified tem-
plate with a new name.
After measuring points have been selected for display, the sampling time must be entered.
Recording starts once the “OK” button is clicked!
After setting the sampling time, the measuring points for the measured data list are selected and then,
in similar fashion, the measuring points for the y(t) graph.
Note: The “Available functions” dialog box is minimized before the graphical display of the data. To stop
the recording of measured data, for example, the window must be maximized again.
See also:
• The section “Stop recording measured data”
• The section "Analyze measured data"
• The section "Select active trigger"
• The section "Recording properties"
• The section “Offline and online Y(t) graph”
Select active trigger

Measuremed data recording can also be started by trigger conditions. A trigger can be composed of
one or more logically linked start or stop conditions. If the trigger condition is met then the recording of
measuremed data starts or stops.
A trigger definition (creating triggers) is only possible on the menu-based user interface.
The trigger is selected in the following window:
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Figure 45: Selecting an active trigger
Stop measured data recording

Stops the data recorder. The recording can be stored with a user-defined file name by clicking the “Yes”
button.

Figure 46: Recorded data
Figure 47: Save file as

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Analyze measured data

Opens saved data for offline processing.

Figure 48: Opening recorded data
This dialog box is used for selecting measuring points.
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Figure 49: Selecting measurement points for the y(t) graph

Option Description
Available meas- Available measuring points for the selected recording
uring points
Stored graphics Here you can select a stored group
or lists
Selected for dis- List of the selected measuring points
play
Select all measuring points
Selects the marked measuring points in “Available measuring points”. Single measuring
points can also be selected by double-clicking.
To select multiple measuring points, drag your mouse over the desired measuring points
or click on several measuring points while keeping the Ctrl key pressed.
Deselects marked measuring points in “Selected for display”. Single measuring points
can also be deselected by double-clicking.
To deselect multiple measuring points, drag your mouse over the desired measuring
points or click on several measuring points while keeping the Ctrl key pressed.
Deselect all measuring points
Templates
Export Available templates for selecting the measuring points for the Y(t) graph can be copied
into a non project-specific template database from within the current device description.
They can then be copied to another device description via “Import” at a later date.
Import Templates for the selection of the measuring points for the Y(t) graph can be copied to
the current device description from the non project-specific template database.
Time interval Here you set the time period shown when opening the Y(t) graph.
Note: If the settings specified on the user interface menu under Tools | Settings | Y(t)
Graph specify that the entire graph is to be displayed on opening then the time interval
setting has no effect.
Additionally, an extra time interval can be defined (“Time interval” button). The data is graphically dis-
played when the “OK” button is pressed.
See also:
• The section “Start recording measured data”
• The section “Stop recording measured data”
• The section “Offline and online Y(t) graph”
Offline and online Y(t) graph
Window
This window shows the progression over time of the measured data.
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Figure 50: Offline view of y(t) graph
1 Reference to the measur- 2 Unit 3 Measurement points list
ing-point list
Measurement points list
A All relevant functions have an effect

on the selected measurement
points. The color-coding matches
the color in which the curve is dis-
played on the graph.
B Reference to axis
C Device number
D Measuring point number
E Measurement point name
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Figure 51: Measurement points list
Note: The print function is invoked by the key combination Ctrl + P.
Context menus for offline and online Y(t) graphic

4 context menus can be opened in the following areas (pop-up menus, hover mouse over area con-
cerned and click right mouse button).

Figure 52: Absolute scale – Time – Grid
1 Y-axis lable 3 Display range
2 Y-axis lable 4 Measurement points list
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5.2 Parameters
Edit single parameters
First, a window opens where you can select single parameters.
Figure 53: Selecting individual parameters

The selected parameters are then shown in a window. The properties window is opened by pressing key
combination Ctrl + Alt + P.
Notes:
You can alter the width of the selection windows (Edit single parameters, Edit 2D parameters and Edit
3D parameters).
You can alter the height and width of the input windows (Single parameters, 2D parameters and 3D
parameters).
When device type “ECU-7” is selected, there are additional special windows for entering single parame-
ters (refer to the sections “Edit input and output settings” and “Edit protection/monitoring parame-
ters”)
See also:
• The section “Edit 2D parameters”
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• The section “Edit 3D parameters”
Edit 2D parameters
First, a window opens for selecting the characteristic curve (2D parameters).

Figure 54: Selecting 2D parameters
The selected characteristic curve is then shown in a window.
Edit 3D parameters
First, a window opens for selecting a performance map (3D parameters).
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Figure 55: Selecting 3D parameters
The selected performance map is then shown in a window.
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5.3 Injector code
Note: Only available for ECU-4 control units.
Figure 56: Entering injector code
If the injector codes have been changed and the “Send” button has been clicked then a window of this
type is displayed:
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Figure 57: Comparing PC data and active data

If you wish to make the changes, the data can be sent to the control unit by clicking the “Send” button
again.

5.4 Send changed data to control unit
When parameters are changed, a window of the following type appears:
Figure 58: Comparing PC data and active data

Transfer of the modified data to the control unit starts once the "Send" button is pressed.
Clicking the “Cancel” button, returns you to the previous window.
Option Description
ParNo Parameter number
Parameter Parameter name
Type Type of the modified parameter (dimension, axis with index)
PC value New value to be transferred
Active value Old value to be overwritten
Unit Measurement unit of parameter
For 2D and 3D parameters a confirmation window appears (except for ECU-7):

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Figure 59: Serial interface driver
Note: If all parameters are identical, the following window will open: Please click the “OK” button.
Figure 60: Comparison result

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5.5 Download control unit
Notes:
• Only available for control units ECU-1, ECU-4, ECU-7, ECU-183 and CDS/CR.
• CDS/CR is described in the next section!
Engine data records (functional software and engine parameter sets) can be copied to the control unit.
They must be available in the local database. Two functions are provided:
• 1. Download engine parameter set to control unit
• 2. Delete control unit and download new data (not available for MDEC-ECU C1)
The first function must always be used.
Exception: the control unit hardware has been replaced and the control unit needs to be completely
deleted and re-downloaded. The second function may only be used in this case.
Figure 61: Downloading control unit
See also:
• The section “Download engine parameter set to control unit” (only possible online)
• The section "Delete control unit and download new data" (only possible offline)
Download engine parameter set to control unit

Note: Only available for control units ECU-1, ECU-4, ECU-7 and ECU-183.
This is the normal function when engine parameter sets are to be copied from the local database to the
control unit.
The requirement for this is that a connection to the control unit has been established (online mode).
Additionally, the engine number from the device description and the control unit must exist in the local
database. The parameters on the control unit are deleted and rewritten. DiaSys decides whether it is
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necessary to copy new FSW onto the control unit. If it is found that the engine parameter set in the
local database is older than the one on the control unit, then confirmation is explicitly requested from
the user:

Figure 62: Database server prompt to save
If the entries in the local database are from a later date then the engine parameter set is immediately
copied without delay.
See also:
• The section "Delete control unit and download new data"
Delete control unit and download new data

Note: Only available for control units ECU-4, ECU-7 and ECU-183.
ECU-4: The load profile data of the control unit is deleted by this measure and no longer automatically
transmitted to the control unit. The maintenance predictor may only be backed up once the engine has
stopped.
Caution: All data (operating hours, load profile, etc.) on the control unit is deleted. The engine parame-
ter set and the functional software is then subsequently re-downloaded.
The requirement for this is that the engine number from the device description is available in the local
database. In this case, for this function to be invoked at all, a connection to the control unit must not
have been established (offline mode) (see section “Establish connection to control unit”).
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Figure 63: Online data connection to device
This dialog box must be confirmed by pressing “OK” as shown above in order to establish an offline
connection. The previously shaded out button “Delete and retransmit to control unit” is then once more
available. The connecting cable between the computer and the control unit must be connected as data
is to be exchanged (programming mode, refer to section “Terms and definitions”).
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Figure 64: Confirmation prompt for downloading new FSW and MPS
Click the “OK” button to transfer FSW and MPS data to the control unit.

Figure 65: Serial interface driver prompt to switch off
control unit
As shown by the order of the windows above, the following steps must be performed in the order indi-
cated:
• Switch off the control unit.
• Confirm by clicking “OK”.
• Switch the control unit back on within 30 seconds.
Figure 66: Sending FSW to control unit
Transmission starts once all requirements have been fulfilled (indicated by the following animation):
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Figure 67: Data transfer
Note: Please be patient. The time required for data transfer is not known in advance and may be up to
10 minutes.
Figure 68: Prompt to switch control unit off and on again
Note:
• To now complete the process of applying the re-downloaded data on the control unit, it must under-
go a “power-on reset”. The control unit must therefore be switched off and then back on (not for
ECU-7). This must be confirmed by pressing OK in the dialog box illustrated above.
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The control unit then loads the data that has been transferred and is then ready for operation.

Figure 69: Receiving control unit data
See also:
• The section "Download engine parameter set to control unit"
Download control unit (CDS/CR control unit only in this case)

Note: this section only relates to the CDS/CR control unit.
The function can be carried out in offline mode with a serial connection from the control unit to the PC.
After entering the software code number, transfer of data to the control unit is started.
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Figure 70: Programming CDS/CR control unit

5.6 Log files
The illustration below shows an overview of the available log files.
Figure 71: Log files

Functions in LOG FILES with Level 1B E E E E E E C C R
hardware key, depending on control C C C C C C D D 0
unit U U U U S U S S 8
- - - - - - / / 2
7 4 2 1 U 1 C C
N 8 R
I 3
Error log file X X — X X X X O —
Delete error log file X X — X X X — X —
Export error log file — X — X X X X X —
Modification log file X X X X X X X X —
Parameter modified by X X — — X X X X —
EOL parameter modified by — — — — — — X — —
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Display device information — — — — — — X — —

Device ID — X X X X X X X —
— = Function not available
O = Available/not available depending on control unit functional software

Error log file
Note: The window contents are different for the ECU-7. Not all CDS/C functional software supports this
function.
Opens a window displaying the error messages (error log file). Sorts the error messages chronological-
ly.
Figure 72: Chronologically ordered error messages

A pop-up menu can be opened with the right mouse button:
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Figure 73: In chronological order

Delete error log file
Note: Not all CDS/C functional software supports this function.
The contents of the error memory on the control unit are deleted.
Export error log file

Note: Not available for ECU-7 control unit. Not all CDS/C functional software supports this function.
The contents of the error memory are exported to an Excel file.
Modification log file

Parameter changes are automatically recorded by DiaSys. Opens the window for showing the parame-
ter changes.
Figure 74: Activity log

The parameter changes made via the opened device description are logged.
The following actions are logged:
• selection of a device
• parameter changes
• import operations
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• opening the device description

The following is shown in the window:
• date/time
• type of activity (with addditional detail where required)
• description:

Type Description
Use Opened by the user
Dev Device selected
Cha Parameter change
Note: This information is also deleted on deleting the device description.
Parameter changed by...

Note: The window contents are different for the ECU-7.
Parameter changes are logged and stored on the control unit. This function opens a window showing
the log. The log records details of who has made changes to the parameters. The date of the change is
also recorded.
Figure 75: User log file
Note: This information is stored on the control unit.
EOL parameter modified by

Displays modigication history of the EOL parameters and the engine configuration.
Display device information

Information on the connected hardware is displayed.
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Device ID
Shows information on the control unit such as the number of error messages. Layout and content de-
pends on the control unit concerned.

Figure 76: Device identification
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5.7 To menus
Depending on the hardware key, the control unit and the user group selected, you can change over to
the menu-based user interface.
More functions are available on the menu-based user interface. It is intended for the experienced user.
You can return by selecting the menu option "Tools – Task-based operation".
Note: A connection to the central database cannot be established from the menu-based user interface.
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5.8 Operating data
Figure 77: Operating data
No. Description
1 Load profile The load profile is shown as a 3D graphic and as a 50*50 matrix in hours (or
can be changed to seconds using the right mouse button).
The “Engine speed” and “Set torque” values are used for division of the load
profile.
The load profile can be rotated around all axes using the mouse. If the
mouse has two buttons, press and hold both buttons and rotate the curve
by moving the mouse. If the mouse has three buttons, press and hold the
center mouse button.
2 Load change counter The load change counters for engine, TC 1, TC 2, TC 3 and TC 4 (selectable
using the right mouse button) are shown as a 3D graphic and a 15*15 ma-
trix.
Load change counting involves recording the monitored reading (specified
torque or turbocharger speed 1 - 4) in a “from-to” matrix.
3 Turbocharger switch- The turbocharger switching counter is shown as a 3D graphic and a 10*10
ing counter matrix.
The turbocharger switching counter records the turbocharger status in a
"from-to" matrix.
4 Start counter The coolant temperature and oil temperature start counters (selectable us-
ing right mouse button) are shown as 2D graphics and value lists.
After each completed start, a check is made as to whether the measured
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reading fment value is within the start counter temperature classes. If so,
then the appropriate counter is increased by one.
5 Revolution counter The oil pressure revolution counter is shown as a 2D graphic and a value
list.
When the engine is started with low oil pressure (< 1.0 bar ), the engine rev-
olutions are counted below 300 rpm and then classified according to the oil
pressure.
Note: A context menu can be opened using the right mouse button. From there you can produce a
printout. It is also used to change the views.

5.9 Maintenance predictor
Note: Only available for control units ECU-1, ECU-7 and ECS-UNI.
The following illustration shows an overview of all functions related to the maintenance predictor.
Figure 78: Maintenance predictor

Functions in MAINTENANCE PREDIC- E E E E E E C C R
TOR with Level 1B hardware key, de- C C C C CS C D D 0
pending on control unit U U U U - U S S 8
- - - - U - / / 2
7 4 2 1 N 1 C C
I 8 R
3
Confirm scheduled maintenance — — — — X — — — —
Sched. maintenance dates — — — — X — — — —
Move scheduled dates — — — — X — — — —
Load-dependent maintenance dates — — — — X — — — —
Confirm load-dependent maintenance — — — — X — — — —
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Load profile — X — X X — — — —
Service life matrix — — — — X — — — —
TBO Parameters — — — — X — — — —
Maintenance date tolerances — — — — X — — — —
Modify K factor — — — — X — — — —
New Ti matrix — — — — X — — — —
Restore... — X — X X — — — —

Functions in MAINTENANCE PREDIC- E E E E E E C C R
TOR with Level 1B hardware key, de- C C C C CS C D D 0
pending on control unit U U U U - U S S 8
- - - - U - / / 2
7 4 2 1 N 1 C C
I 8 R
3
Save all (for restore) — X — X X — — — —
Save data for analysis — X — X X — — — —
- = Function not available
Confirm scheduled maintenance

Note: Only available for ECS-Uni.
Scheduled maintenance dates are acknowledged here. The maintenance interval and due date are
shown in the window.
Select the appropriate maintenance interval and click the “Confirm” button.
See also:
• The section "Sched. maintenance dates"
Sched. maintenance dates

The log for scheduled maintenance dates is shown here.
The dates are shown in chronological order. If completion of the maintenance has been confirmed then
the date of maintenance is shown.
See also:
• The section “Confirm scheduled maintenance”
Move scheduled dates

The defined scheduled maintenance dates can be moved in their entirety by a certain time period.
The dates can be shifted by a maximum of 240 months. In the case of “Approaching maintenance
date”, the next maintenance date is before the shift. In the case of “New date”, the new date is after
the shift.
Enter the number of months by which the maintenance date is to be shifted and click the “OK” button.
See also:
• The section “Confirm scheduled maintenance”
Load-dependent maintenance dates

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This shows the log for load-dependent maintenance.
The log includes details of how many operating hours have elapsed after a maintenance service has
been acknowledged (completed). The difference from the due date is shown under “Difference”.
See also:
• The section "Confirm load-dependent maintenance"

Confirm load-dependent maintenance
This window is used to acknowledge load-dependent maintenance. Select the maintenance date to be
confirmed and click “Confirm”. The remaining interval in hours is shown in the right-hand column. You
can also see here whether maintenance is due.
The current operating hours are shown under “Operating hours”.
See also:
• The section "Load-dependent maintenance dates"
Load profile
Displays the load profile of the connected device.
The load profile graph can be rotated around all axes using the mouse. If the mouse has two buttons,
press and hold both buttons and rotate the curve by moving the mouse. If the mouse has three buttons,
press and hold the center mouse button.
Figure 79: Load profile

Note: To use the data for an analysis it must be saved to a disk using the function “Save data for analy-
sis” as described in the section "Save data for analysis".
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A context menu pops up when you right-click in the gray area between the data window and the view
window.

Figure 80: Load profile context menu
The next and the previous levels can be displayed by pressing “Alt >” and “Alt <” respectively.
Service life matrix

Shows the engine's service life matrix (Ti matrix). The expected life of the engine can be obtained from
it. The service life matrix of the engine is constant and defined by MTU.
The service life graph can be rotated around all axes using the mouse. If the mouse has two buttons,
press and hold both buttons and rotate the curve by moving the mouse. If the mouse has three buttons,
press and hold the center mouse button.
A context menu pops up when you right-click in the gray area between the data window and the view
window.
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Figure 81: Service life matrix
TBO parameters

This window is for viewing and entering TBO parameters. The figures on the left can be edited. The val-
ues to the right are planned or current values.
If data is changed then you can accept the new data by pressing the "Close" button or discard them by
pressing “Cancel” .
Figure 82: TBO parameters

Option Description
TBO The expected lifetime of the engine
Operating hours Operating hours of the engine
Offset Time by which maintenance services have been carried out too early.
This time is subtracted from the calculated lifetime of the engine.
K-constant A constant defined by MTU
Start-TBO A constant defined by MTU
Max. TBO A constant defined by MTU
TBO Offset A constant defined by MTU
Speed (0) Idling speed of the engine
FRP (0) Fuel rack position when engine is idling
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Power (0) Engine power output at idling speed

Speed (max.) Maximum speed of the engine
FRP (max.) Fuel rack position when engine is at full throttle
Power (max.) Maximum power of the engine
FRP factor Calibration factor
FRP offset Calibration factor offset
See also:
• The section "K factor"

Maintenance date tolerances
New tolerances for acknowledging the load-dependent maintenance dates are set in this window.
The tolerance within in which acknowledgement can be made can be set for each maintenance type.
The tolerances are stated as percentages of the due date.
Modify K factor
This window is used to change the K factor.
The K factor is a value defined by MTU.
Note: This function must be carried out when the engine is not running. The load profile must be saved
beforehand (see the section “Save all for restore”).
New Ti matrix
This allows a new service life matrix (TI matrix) to be read from a disk.
Clicking “Browse” opens a file selection window for selecting the appropriate file. The file must have the
extension "mit". The TI matrix is transferred directly to the device
Note: This function must be carried out when the engine is not running. The load profile must be saved
beforehand (see the section “Save all for restore”).
Restore...
Restores a previous backup of the maintenance predictor from disk. The disk used for this must have
been created using the function “Save all (for restore)”.
This is necessary after replacing the hardware, for example.
Caution: restoring the maintenance predictor may only be carried out when the engine is not running.
See also:
• The section “Save all (for restore)"
Save all (for restore)

Saves the data from the maintenance predictor to disk so as to be able to restore it at a alter date (see
also the section “Restore”). You should have a blank, formatted disk ready for this.
This data can not be used for an analysis. For that, you must use the function described in the section
“Save data for analysis”.
A progress bar is shown on the status bar. Follow the instructions in the dialog box.
Caution: the maintenance predictor may only be backed up when the engine is not running.
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See also:
• The section "Restore"
Save data for analysis

Saves the data (load profile, etc.) in Excel format for later analysis.

6 Extras
6.1 General functions in "Tools"
Displays the active hardware key information, the engine number (the apperance of the “Tools” window
differs slightly depending on the control unit).
Figure 83: Overview screen
Export to Excel file

The current
• parameter values
• error messages (for ECU-7 only with DiaSys 2.50 or later)
• maintenance predictor data (for ECU-7 only with DiaSys 2.50 or later)
• modification logs
can be exported to any directory as required.
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Figure 84: Exporting an Excel file
Hardware key info

This window shows information on the hardware key.
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Figure 85: Hardware key

Item Description
Registered user Registered user
Serial number Serial number of the hardware key
Validity period Shows the date up to which the hardware key is valid.
94 | Extras | E531920/05E 2013 - 04

Item Description
Authorization level Shows the authorization level enabled by the hardware key.
Authorization for Shows which devices authorization applies to. The registered user has
write-access to those device types only.
Show alive signal

The data content of the system alive signal for the ECU-7 and the CAN devices connected to the CAN
bus (field bus) can be displayed.
Figure 86: Alive signal
Show ECU-7 “alive” signal

The data content of the “Alive” signal for the ECU-7, which is periodically transmitted via the CAN bus,
is shown.
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Figure 87: ECU communication
Bit Text Meaning

0 Application active 0: Application loader active
1: Application active
1 Engine running 0: Engine not running
1: Engine running
2 Light mode 0: Control unit operating in normal mode
1: Control unit operating in light mode (at least one parameter set mod-
ule is not available on the control unit)
3 Life data Backup active 0: ECU life data backup is not active
1: ECU life data backup is active
4-7 Currently not defined
Source info Here, the contents of bit numbers 7 to 0 are shown as decimal values.
Bits not yet defined by DiaSys are also shown.
Example:
Bit 0 set
Bit 1 set
Source info is then 3
Version Shows the version, edition number and beta number (for released soft-
Edition major ware, the beta is always 0)
If the control unit software is present on the control unit then the ver-
Edition minor sion, etc., of the system software is shown.
Beta If there is no control unit software on the control unit then the version,
etc., of the application loader is shown.
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Show engine number

Note: Only available for control units ECU-4, ECU-7, ECU-183 and CDS/CR .
The engine number is stored internally. This number can be displayed by means of “Show engine num-
ber”.
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Figure 88: Engine number
Calibrate actuator
Note: Only available for CDS/C control units.
Due to the tolerances of injection mechanisms, there is a certain degree of variation in the performance
of standard production or fully overhauled engines. To compensate for the performance tolerances, all
engines undergo a performance calibration process after production. The “Calibrate actuator” button
provides the user with extensive guidance on performing this task.
Test actuator
The “Test actuator” button is intended for maintenance and customer service mechanics. With its help,
it is possible to move the fuel rack from zero to full throttle position when the engine is not running.
Jamming and stiffness of the fuel rack can be identified in this way.
Delete functions
The following delete functions are available:
• Load profile and operating hours
• Cyclical switch
Injection volume calibration

The window for calibrating the injection volume is displayed.
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Torque calibration
The window for calibrating the torque is displayed.
Edit engine configuration

The window for setting the engine configuration is displayed.
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Data provision
There are two functions available under “Data provision”:
• “Control unit replaced”
• “Life data”
Data is read from the CDS/CR control unit and made available so that it can later be transmitted to the
central database. If the data is to be made available after the control unit has been replaced then “Con-
trol unit exchanged” must be used.
If only the “Life data” of the control unit is to be made available for the central database then “Life
data” should be used.
Show load profile

Note: Only available for CDS/C and CDS/CR control units.
The load profile is shown as a 3D graphic and as a 32*32 matrix in hours (or can also be changed to
seconds via the right mouse button).
The load profile can be rotated around all axes using the mouse. If the mouse has two buttons, press
and hold both buttons and rotate the curve by moving the mouse. If the mouse has three buttons, press
and hold the center mouse button.
Select language
The language of the device description (parameter and measuring point texts) can be selected via this
function. DiaSys does not have to be restarted.
Furthermore, the language of the DiaSys interface can also be switched over. To do this, you must close
DiaSys and then restart it.
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Show header information

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Window
Figure 90: CCD header
Function for advanced users

Displays the information from the header of the descriptor module and the parameter module of the
engine and plant.
Read out leakage map

The leakage map can be read out from the control unit. This leakage map can not be displayed by Dia-
Sys. After transfer, a message indicating successful completion and the file name and location appears.
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Figure 91: Leakage map
Read out crash recorder

The crash recorder module can be read out from the control unit. The information contained in the mod-
ule can not be displayed by DiaSys 2.40. After transfer, a message indicating successful completion
and the file name and location appears.
Show CCS info

The CCS info of files with CCS structure can be displayed.
Show hardware CCS


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The CCS info of the hardware is displayed.
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Figure 92: CCS INFO - D:\PROJEKTE\...- HARDWARE-CCS
Show CCS tree


The CCS info of the control hardware and software unit is displayed.
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Figure 93: CCS INFO - D:\PROJEKTE\... - CCS-TREE
Edit alarm parameters

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Figure 94: Edit alarm parameters
102 | Extras | E531920/05E 2013 - 04

The alarm parameter to be edited is selected at the top right. Using the and
arrows, you can move to the previous/next alarm parameter.
In the “Active” column, you can set the attributes of the parameter selected in the “Name” column.
Edit input and output settings

Figure 95: Input/Output settings – Engine signals

The engine transistor outputs TO1 to TO4 can be configured here:
• Assignment to a process variable
• Signal inversion: not inverted/inverted
– Not inverted: if the value of process variable = 1, then current is applied to TO
– Inverted: if the value of process variable = 0, then current is applied to TO
• Wire break/short-circuit monitoring: yes/no
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Figure 96: Input/Output settings – System signals
The plant transistor outputs TOP1 to TOP4 can be configured here:
• Signal inversion: not inverted/inverted
– Not inverted: if the value of process variable = 1, then current is applied to TOP
– Inverted: if the value of process variable = 0, then current is applied to TOP
• Wire break/short-circuit monitoring: yes/no
• Switch: High Side/Low Side
– High Side: 24 V connected
– Low Side: ground connected
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Figure 97: Input/Output settings – Analog signals
Analog outputs AO1 and AO2 can be configured:
• Gain (factor)
• Offset in volts
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Figure 98: Input/Output settings – Binary signals
The binary inputs (channel 0 to channel n) can be configured:
• Channel active: yes/no
• Input (ECU input channel)
• Active High: yes/no
• Rebound time in seconds
• Sensor defect delay in seconds
• Use substitute value if sensor defective: yes/no
Edit protection/monitoring parameters

Note: Only available for ECU-7 control units that also support this function together with DiaSys 2.40
SP1.
If the function is not supported by the control unit then the following message appears:
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Figure 99: Parameters
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Figure 100: Monitoring/Protection module: protection parameters

The protection/monitoring parameter to be edited is selected in the “Limit” box. Using the
and arrows, you can move to the previous/next parameter.
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The mode is selected in the “Protection mode” selection box on the “Protection” tab. The correspond-
ing protection parameters can then be set in the lower part of the window.
Figure 101: Monitoring/Protection module: monitoring parameters

The corresponding monitoring parameters are set on the “Monitoring” tab. If there is a corresponding
limit graph, it can be opened directly from within this window
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6.2 Reset Functions
6.2.1 General information on reset functions
As part of exhaust-related maintenance work, the following operations at most may be carried out, de-
pending on engine model and its engine management control unit:
• Replace oxygen sensor
• Replace DOC diesel oxidation catalytic converter
• Replace DPF diesel particulate filter
• Replace EGR valves
• Replace DPF exhaust flap
• Replace NOx sensor (nitrogen oxide sensor)
Engine models and operations

The following table details which operations are possible on which engines:
Work 4000/0 4000T, R, G, 2000T, C, R, 1600Gx0 New DiaSys
3 C ... -04 S...-06 1600Gxx
Replace NOx(5) - YES YES YES YES No action re-
quired
Replace oxygen - YES YES YES YES Reset oxygen
sensor(2) sensor
Replace DOC(1) - YES YES YES YES Reset DOC
Replace DPF(1) - YES YES YES YES Reset DPF
Replace EGR - YES YES YES YES Replace valves
valves(3)
Replace DPF ex- - YES YES YES YES Replace valves
haust flap(3)
Replace injec- YES YES YES YES YES Injector re-
tors(4) placement
with/without
IIG
: For the operations marked (1), the reset operations specified in the DiaSys column have to be per-
(1)
formed with the aid of DiaSys.

: Replacing the oxygen sensor is a special case. Although the sensors used today reset themselves
(2)
automatically, a manual reset is nevertheless recommended as calibration is then immediately per-

formed. Afterwards, the engine should be started and then stopped again.
: After replacing one of the valves it is necessary to perform a "learning run". That allows the control
(3)
unit to learn the limit points of valve movement. Therefore, it is important to ensure that the valves can
travel through their full range of movement without hindrance during the learning run (no mechanical
obstructions).
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When the control unit is initialized the valves are moved to the "learned" limits in order to check the
valves.
(4)
: Whether with or without IIG depends on the control unit software.
(5)
: The NOx sensor resets itself automatically.
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6.2.2 Resetting DOC and/or DPF
Preconditions
☑ Diesel oxidation catalytic converter (DOC) replaced and/or
☑ Diesel particulate filter (DPF) replaced
☑ Device description is open.
☑ Connection between DiaSys and engine control unit is established.
Select function: "Tools" – "Reset functions"

1. Selecting this function opens a window.
2. The window elements have the following
meanings:
• "AGN reset functions (DOC and DPF ..."
button: resets figures stored for emis-
sion control systems.
• "Oxygen sensor reset function" button:
resets the oxygen sensor.
Figure 102: Selecting "Reset functions"
Procedure
1. Replace diesel oxidation catalytic converter.
2. Connect DiaSys and establish connection to engine control unit.
3. Select function "Tools" – "Reset functions".
4. Select button "AGN reset functions (DOC and DPF) ...".
Result: The following window opens:
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Figure 103: Warning window
5. Enter the hardware key number (in the above example, 290475).
6. Select the “Next” button.
7. Select the checkbox(es) according to the
operations carried out on the engine.
8. Select the “Execute” button.
Result: The ECU data (CDC calibration drift com-
pensation for DOC and/or DPF) is reset to
the initial values for the relevant area(s).
The message "Function successfully com-
pleted" appears.
9. Click “OK” button.
Figure 104: DOC and/or DPF selection window
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6.2.3 Resetting oxygen sensor
Preconditions
☑ Oxygen sensor replaced
Select function: "Tools" – "Reset functions"

2. The window elements have the following
meanings:
• "AGN reset functions (DOC and DPF ..."
button: resets figures stored for emis-
sion control systems.
• "Oxygen sensor reset function" button:
resets the oxygen sensor.
Figure 105: Selecting Reset functions
Procedure
1. Replace oxygen sensor.
2. Select function "Tools" – "Reset functions".
3. Select "Oxygen sensor reset function" button.
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4. Enter the hardware key number (in the above example, 290475).
Result: The ECU data (CDC calibration drift compensation for the oxygen sensor) is reset to the initial values for
the relevant area(s). The message "Function successfully completed" appears.
6. Click “OK” button.
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6.2.4 Teaching valve limits
Preconditions
☑ Valve concerned has been replaced
☑ Valve moves freely up to end stops in both directions
☑ No obstructions preventing movement of valve lever or linkage
Select function: "Available functions" – "Edit single parameters"

Figure 107: Selecting individual parameters

2. The window elements have the following meanings:
• ">" button: places the selected parameter in the "Selected for display" box.
• ">>" button: places all parameters in the "Selected for display" box.
• “OK” button: enables the parameters in the "Selected for display" box for editing.
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Procedure for activating learning mode:
1. Replace defective valve.
2. Select function "Available functions" – "Edit single parameters".
3. Select the following parameters for the valve concerned:
• Learning sequence for EGR valve A (exhaust gas recirculation valve A): 1.0700.016
• Learning sequence for EGR valve B (exhaust gas recirculation valve B): 1.0700.035
• Learning sequence for DPF exhaust flap (bypass valve): 1.0700.055
• Learning sequence for dispenser valve: 1.0700.075
• Learning sequence for air intake valve: 1.0700.166
4. Enter an "X" in the column "PC data".
5. Select the "Send (F11)" button.
Result: The "Compare PC and active data" window opens.
6. Select the "Send" button.
Result: The selected valve runs once through its full range of movement. The end stops (limit positions) thus
identified are stored by the ECU (as 0% and 100% respectively). The movement limits for the valve have
then been successfully learned.
Exiting learning mode

Important
On successful completion of the learning sequence for the valves (see above), learning mode must be exit-
ed.
1. In the column "PC data" clear the "X" for the parameter concerned by selecting it.
2. Select the "Send (F11)" button.
Result: The "Compare PC and active data" window opens.
3. Select the "Send" button.
Result: The engine management control unit is returned to normal operating mode.
4. Close the "Edit single parameters" window.
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6.3 Injector Functions
6.3.1 General information on injector functions
The following functions are available for the injectors:
• Injector shutdown
• Injector test (with function Show analysis)
• Injector replacement
Resetting the injectors after injector replacement

The following table summarizes which operations are required on which engines when injectors have
been replaced:
Work 4000/03 4000T, R, G, 2000T, C, R, 1600Gx0 New DIASYS
C ... -04 S...-06 1600Gxx
Injector re- ■ - - - - Injector re-
placement – placement with-
w/o IIG out IIG
Injector re- - ■ ■ ■ ■ Injector re-
placement – placement –
with IIG with IIG
Notes on CDC calibration drift compensation for injectors and IIG initial
injector equalization
CDC calibration drift compensation
Injector characteristics change over the life of the injector.
In order to ensure that injection quality remains constant and that optimum emission and consumption
characteristics are maintained, the ECU engine management control units incorporate a function that
compensates for such "drift". The drift compensation function (CDC calibration drift compensation) has
to be calibrated, i.e. reset after injectors are replaced (with new or reman components) so that the
compensation starts from the beginning again. That ensures constant emission levels and, therefore,
that the engine meets the legal requirements.
Notes:
Software versions earlier than 1.12 (ECU 7) do not have the drift compensation function. No input win-
dow appears. Nevertheless, availability should always be checked.
Replacing injectors with injectors from another engine that have completed more than 50 hours of duty
is not possible because stored data on the injectors is no longer available.
IIG initial injector equalization

Note:
TIM-ID: 0000040101 - 002
With ECU 7, the injector code input window (see IIG below) is not shown. There is nothing to do in this
case.
New injectors are provided with a DMC (Data Matrix Code) and an HRC (Human Readable Code). In the
case of ECU engine management control units that have the function (initial injector equalization), the
input window for the CDC (opened via "Tools – Injector functions – Injector replacement") includes the
boxes "Old code" and "New code" below the duty hours boxes. If a new injector is fitted, the HRC
marked on the injector should be entered here.
Background
The injection characteristics of injectors are not entirely identical.
116 | Extras | E531920/05E 2013 - 04

Effect on engine management control unit
Entering the HRC allows the engine management control unit to analyze the information thus provided.
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6.3.2 Injector replacement without IIG
Preconditions
☑ Engine management control unit has software that does NOT support IIG initial injector equalization
(e.g. ECU 7)
☑ Injector(s) replaced; in the example illustrated below, injector A2 has been replaced.
Select function: “Tools” — “Injector functions” — “Injector replacement"

Figure 108: Input window for injector replacement without IIG

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118 | Extras | E531920/05E 2013 - 04

• Button “Tag all”: selects all buttons from "A1 to Axx" and "B1 to Bxx".
• Button “Untag all”: deselects all buttons from "A1 to Axx" and "B1 to Bxx".
• Buttons “A1 to Axx” and "B1 to Bxx”:
– xx for 8-cylinder engines = 4
When the button is selected, the corresponding display boxes for “Operating hours" and “Virtual run-
time" are set to "0".
• "Operating hours" display box: Operating time of the engine with the relevant injector installed.
• “Virtual runtime” display box: Weighted runtime of the relevant injector (for internal analysis by MTU)
• “Save” button: saves the changes entered
• “Undo” button: reverses the last save operation. However, this is only possible as long as the current
“Injector replacement” window is open.
• "Close" button: closes the current "Injector replacement" window.
Procedure
1. Replace injector.
3. Select function “Tools” — “Injector functions” — “Injector replacement".
TIM-ID: 0000017222 - 002
Figure 109: Input window example: injector A2 replaced

4. Select buttons for all injectors replaced (in the illustration, only injector A2 has been replaced).
Result: The times shown in the “Operating hours” and “Virtual runtime” display boxes for all injectors that have
been replaced are set to “0”.
Save
1. Select “Save” button.
Result: A warning window will then appear.
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2. In the input box enter the number of the hardware key used.
3. Select “Next” button.
Result: The data entered is saved to the engine management control unit. The engine will now operate with the
new data.
“Undo” function
Note: This function allows the user to undo the last save operation if the wrong injector has been selected by
mistake.
1. Select “Undo” button.
Result: All previous operating hours times are retrieved and displayed in the “Operating hours” display boxes.
2. Resetting the operating hours for replaced injectors can be restarted. TIM-ID: 0000017222 - 002
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6.3.3 Injector replacement – with IIG
Preconditions
☑ Engine management control unit has software that supports IIG initial injector equalization (e.g. ECU
8 or 9)
☑ Injector(s) replaced; in the example illustrated below, injector A2 has been replaced.
Select function: "Tools" – "Injector functions" – "Injector replacement"
Figure 111: Input window for injector replacement with IIG

u The window elements have the following meanings:
• "Select all" button: selects all buttons from "A1 to Axx" and "B1 to Bxx".
• "Cancel selection" button: deselects all buttons from "A1 to Axx" and "B1 to Bxx".
• Buttons “A1 to Axx” and B1 to Bxx”:
TIM-ID: 0000040383 - 001
When the button is selected, the corresponding display boxes for “Operating hours" and “Virtual run-
time" are set to "0". The "New code" boxes are enabled.
• "Operating hours" display box: Operating time of the engine with the relevant injector installed.
• “Virtual runtime” display box: Weighted runtime of the relevant injector (for internal analysis by MTU)
• "New code" display box: code marked on the injector which contains encoded initialization values for
the injector.
• “Save” button: saves the changes entered
• “Undo” button: reverses the last save operation. However, this is only possible as long as the current
“Injector replacement” window is open.
• "Close" button: closes the current "Injector replacement" window.
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Procedure
1. Note down the injector code(s) marked on the new injector(s) used and make certain of which cylinder
each injector is fitted to.
2. Replace injector.
Result: A warning window will then appear:
Figure 112: Warning window -

5. In the input box enter the number of the hardware key used.
7. The next step involves indicating whether existing injectors have been swapped with one another or
whether new injectors have been fitted.
8. The following steps illustrate how to pro-
ceed if new injectors have been fitted.
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Figure 113: Selecting type of operation
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Figure 114: Input window for injector replacement with IIG
9. Select buttons for all injectors that have been replaced.
Result: The times shown in the “Operating hours” and “Virtual runtime” display boxes for all injectors that have
been replaced are set to “0”. The corresponding "New code" boxes are enabled.
10. Enter the injector codes in the relevant boxes.
Saving
u Select the “Save” button.
Result: The data entered is saved to the engine management control unit. The engine will now operate with the
new data.
“Undo” function
Note: This function allows the user to undo the last save operation if the wrong injector has been selected by
mistake. However, this is only possible as long as the current “Injector replacement” window is open.
1. Select the “Undo” button.
Result: All previous operating hours times are retrieved and displayed in the “Operating hours” display boxes
and the old injector codes reinstated.
2. Resetting the operating hours for replaced injectors can be restarted.
Injectors swapped
Note: This function makes it possible to easily swap the data for two injectors that have been interchanged
TIM-ID: 0000040383 - 001
with one another, without the need for any manual input.
1. Swap over 2 injectors with one another.
Result: The warning window shown above will then appear.
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4. On the input screen, select the two injec-
tors that have been swapped over (in the
example shown, injectors A1 and A3).
Result: The times shown in the "Operating hours"
and "Virtual runtime" boxes for each injec-
tor and the injector codes are swapped
over.
5. Select the “Save” button.
Result: The data entered is saved to the engine
management control unit. The engine will
now operate with the new data.
Figure 115: Interchanging 2 injectors with one another
Warning if IIG function is deacti-

vated
Figure 116: IIG deactivated warning window
Important!
If the window shown above appears, the function has been deactivated by the 1D parameter 1.1025.001
"Enable IIG". In that case it is essential to check why the function has been deactivated. The user must
then decide whether to leave it as it is – normally, however, it should be reactivated.
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6.3.4 Injector test
Preconditions
☑ Engine ready for start
DANGER
Unguarded rotating and moving engine components.
Risk of serious injury – danger to life!
• Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
DANGER
• Take special care when working on a running engine.
Select function: “Tools” — “Injector functions” — “Injector test”

Note: An injector test makes it possible to determine whether injectors are defective or no longer within the
specified tolerances with regard to injection timing and injection period. To that end, in the course of
the test each injector is shut down in turn and the effect on engine speed determined. If it can then be
observed, for example, that after shutting down a particular injector, the operating data does not
change at all, then it is clear that the injector concerned is defective because it is not injecting any fuel.
So shutting down that injector has no effect. There are two alternative test procedures (complete en-
gine or one cylinder bank) in order to be able to take different system parameters into account. For
each alternative there is and .
• A minimum coolant temperature for the test
• Limitations regarding minimum/maximum allowable engine speed and minimum/maximum cylinder
charge (test cannot be performed across the entire engine performance map)
• Suggestions for speed (and/or load) at which engine should be run in order to obtain optimum test
results
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Figure 117: Injector test input/display window
• "Start test" button: initializes and starts the injector test.
• "Stop test" button: this can be used to stop a test in progress.
• "Analysis" button: after successful completion of a test, this button is used to display the results. The
test results can then also be exported to a *.CSV file.
• "Close window" button: exits the test function.
Procedure
2. Select function “Tools” — “Injector functions” — “Injector test”.
3. The "Injector test" window opens.
4. Start engine.
5. Run up the engine to the levels indicated in the "Parameters" box.
6. Press the "Start test" button.
Result: The test will then start. During the course of the test, the "Progress" box shows a series of messages
indicating the current status. Note: a test can take a considerable time (in some cases over 20 mi-
TIM-ID: 0000040227 - 002
nutes), especially on engines with a large number of cylinders. After completion of the test, the results
can be analyzed.
Analysis
1. Select function "Tools" – "Injector functions" – "Analysis".
Result: The following window opens (illustrative example):
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Figure 118: Analysis
Note: In the example above, injector A5 has been found to be defective.
2. Replace the defective injector(s).
3. Select function "Tools" – "Injector functions" – "Injector replacement".
4. Carry out the operations specified in the relevant sections for those functions (see "Injector replace-
ment with/without IIG").
Note: Depending on the engine management control unit software version, it may be that the column "Injec-
tor outside tolerance" does not appear. The columns
• "Engine speed difference (rpm)"
and
• "Volume difference (mm3/stroke)"
are available.
5. In this case users must draw their own conclusions as to the action to be taken as a result.
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6.3.5 Injector shutdown
Preconditions
☑ Engine ready to start
☑ User must have detailed knowledge of interpreting injection volume data for injectors
DANGER
• Before barring or starting the engine, ensure that nobody is in the danger zone.
• After working on the engine, check that all protective devices have been reinstalled and all tools
removed from the engine.
DANGER
• Take special care when working on a running engine.
Select function: "Tools" – "Injector functions" – "Injector shutdown".

Note: The function "Injector shutdown" is a second possibility for identifying defective injectors. In this case,
however, DiaSys does not establish and indicate which injector(s) can be viewed as defective; instead
the user is given precise information (from which the user must draw their own conclusions as to the
measures subsequently to be taken) on the following:
• Engine speed before and after injector shutdown
• Injection volume before and after injector shutdown
TIM-ID: 0000040335 - 002
Figure 119: Injector shutdown
128 | Extras | E531920/05E 2013 - 04

• "Test type on" button: switches on the test function
• "Shut down injector" button: the injectors selected using buttons A1 to B6 (B10) are shut down
• "Switch on injector" button: the injectors selected using buttons A1 to B6 (B10) are reactivated
• "Test type off (normal operation)" button: switches off the test function
• "CSV" button: after successful completion of a test, the results can be exported to a *.CSV file.
• "Close window" button: exits the test function.
Procedure
2. Select function "Tools" – "Injector functions" – "Injector shutdown".
3. The "Injector shutdown" window opens.
4. Start engine.
5. Run up the engine to the levels indicated in the "Parameters" box.
6. Select "Test type on" button:
Result: The test will then start.
7. Select one (or more) injectors by clicking the appropriate buttons.
8. Select the "Shut down injector" button.
Result: The selected injectors are shut down. After a certain amount of time the figures for the injectors appear
in the boxes. The user must then draw his/her own conclusions as to the action to be taken as a result.
9. Select "Switch on injector" button.
Result: The injector(s) are reactivated.
Concluding the test

Note: It is essential that this test mode is correctly concluded so that the engine management control unit
can resume its normal operating mode.
1. Make sure that all injectors are switched on again.
2. Select the "Test type off (normal operation)" button.
Result: The engine management control unit then resumes its normal operating mode. The window can now be
closed. If desired, the test results can be exported to a *.CSV file by selecting the "CSV" button.
TIM-ID: 0000040335 - 002
E531920/05E 2013 - 04 | Extras | 129

7 Program MEM
7.1 Prepare for BDM programming
MEM memory modules can be programmed. To use this function, you require a backup data module
and a suitable connection cable (refer to the following figure).
Figure 120: BDM WITH CABLE

1 Plug for the display 2 Blue heat-shrinkable hose
Cable connector assignment (MTU article no. 535 530 75 34)

Connector assignment is as follows:
9 pin Sub-D FB-1 plug Potential
BDM Display
7 81 61 CAN-H
2 82 62 CAN-L
3 83 63 CAN-GND
TIM-ID: 0000017217 - 002
Note:
• Between pins 81 and 82 the resistance measured should be 60 Ω (bus terminal resistor).
130 | Program MEM | E531920/05E 2013 - 04

Requirements before using
The following requirements must be fulfilled to use this function:
• The interactive PC must be equipped with a CAN board.
• A dongle (hardware key) with CAN customer support access is required.
• There must be a backup data module (BDM) with device software (GSW) V3.02 or later.
• Using the E2_PROGR.OUT program, check whether Option 0 (Station Type) is assigned by PPS (refer
to the following figure)
• There must be four directory levels below the base directory (this is indicated by the BDM settings).
The data must be in the fourth directory. If not, the "Program" button is not enabled. The names and
contents of the higher level directories are of no significance.
• The path for the source of the programming procedure can be selected by means of the buttons
“MCS-5/RCS-5”, “Options”, “BDM Settings” (e.g. CD, Diskette). The directory depth must remain as
it is (see above).
Important: Except for the BDM, the DIS 10 to DIS 13 can also be used for programming the MEM-5
module via the CAN interface. For more details, refer to the DIS description.
Notes:
• Different directories are defined for the basic software and the “PU” data.
• MEM-5 modules previously programmed are overwritten without prompting.
• To program the MEM-5 modules, the BDM and the interactive software must be set to the same baud
rate.
An example of a correct setting is provided in the following example:
TIM-ID: 0000017217 - 002
Figure 121: BDM - HYPER TERMINAL

Note:
• If the transmission rate (Option 3 in the figure above, marked by an *) is not set to 125 kbaud then
the BDM download function (data transmission from the BDM to the plant) no longer functions.
Programming is carried out as follows:

“Product support” must be selected as the activity group (user group).
E531920/05E 2013 - 04 | Program MEM | 131

Figure 122: User group
See also:
• The section "User group"
Device type MCS-5/RCS-5 must be selected.
TIM-ID: 0000017217 - 002
Figure 123: Select device type
132 | Program MEM | E531920/05E 2013 - 04

Prepare for BDM programming

Start preparation by clicking the “Prepare BDM programming” button. In the following window, you
must indicate whether the directory structure for configuration data (PU) or basic software is to be cre-
ated.
TIM-ID: 0000017217 - 002
E531920/05E 2013 - 04 | Program MEM | 133

Figure 125: Creating BDM directory structure
In the next step, you enter the job number and the index number for the job:
TIM-ID: 0000017217 - 002
Figure 126: Creating PDM directory structure for PU data (1)

The available data must then be selected:
134 | Program MEM | E531920/05E 2013 - 04

When you click the “Select” button, a window for selecting the relevant file appears.
TIM-ID: 0000017217 - 002
Figure 128: OPEN

Once all required information has been entered, preparation for BDM programming is completed by
clicking the “Execute” button.
E531920/05E 2013 - 04 | Program MEM | 135
TIM-ID: 0000017217 - 002
136 | Program MEM | E531920/05E 2013 - 04

7.2 Programming mode

Select programming mode by clicking on the “Programming mode...” button.
TIM-ID: 0000017221 - 002
E531920/05E 2013 - 04 | Program MEM | 137

Figure 131: BDM programming – Warning
As soon as the requirements for a safe system state are ensured (BDM is connected to the interactive
PC, the power supplies are connected and stable), then you should click the “OK” button.
In the “Data type” pane, you should enter the settings for "PU data” or “Basic software” as shown in the
two windows illustrated below.
TIM-ID: 0000017221 - 002
138 | Program MEM | E531920/05E 2013 - 04

Figure 132: Settings for programming by BDM – PU data
TIM-ID: 0000017221 - 002
Figure 133: Settings for programming by BDM – GSW

The path (directory levels) must match the examples provided above, otherwise the “Program” button is
not enabled.
In the “PCMCIA channel” pane, select the CAN interface used at the PC end.
E531920/05E 2013 - 04 | Program MEM | 139
In the “Baud rate” pane, you can also select a transmission rate of 400 kbaud. However, this presup-
poses that the transmission speed on the BDM has also been set to 400 kbaud using the program
E2_PROGR.OUT. In this case, the BDM download functionality is no longer guaranteed.
This high transmission speed is only suitable for programming the MEM module.
The transmission speed must therefore always be reset to 125 kbaud after concluding the download.
Clicking the “Program” button starts the programming procedure.
The warning referred to above (as shown in the illustration "Ready signal") must again be confirmed.
The interactive system establishes an online connection to the BDM (green panel, bottom right).
If everything has been correctly set, you will see a progress bar for the programming sequence as
shown in the illustration below.
Note:
• Of the maximum possible 32 blocks to be programmed, only the assigned blocks are transferred to
the BDM. In the example shown in the illustration below, they make up a total of only 8 blocks.
Figure 134: BDM programming
After completion of programming, a check window appears showing a log of the programming se-
quence. TIM-ID: 0000017221 - 002
140 | Program MEM | E531920/05E 2013 - 04

Figure 135: Completion of BDM programming
This completes the programming procedure.
Note:
• With older versions (DiaSys, device software) irrelevant error messages appear when programming
the 'PU' data.
TIM-ID: 0000017221 - 002
E531920/05E 2013 - 04 | Program MEM | 141

8 Templates
8.1 Templates
Templates are used for storing collected selection lists within a device description in order to run the
selection faster in the future.
Storing template is - with one exception - only possible on the menu screen. You can also access stored
templates in the button screen.
Attention: Deleting a device description also deletes all templates for this device description.
Templates can be exported and imported (not for device type “MCS-5/RCS-5”), so that they
• can also be used in other device descriptions
• are not lost when deleting the device description.
Create and store templates

Templates can be created from:
• the selection of single parameters
• the selection of measuring points for data recording (also in the button screen)
• arranging the y(t) display
• measurement data lists
• bar graphics
Storage of a template is in the menu screen, each in a newly displayed menu between the “Parameter”
menu and the “Extras” menu.
Exception: The selection of measuring points for data recording is already made in the selection window
and can therefore be made both in the menu screen and the button screen.
TIM-ID: 0000017218 - 001
142 | Templates | E531920/05E 2013 - 04

Save: Selection of single parameters
Figure 136: DIASYS - C:\DIASYS\... - SINGLE PARAMETER
Save: Arrangement of the y(t) display

TIM-ID: 0000017218 - 001
Figure 137: DIASYS - C:\DIASYS\...- Y(T) DISPLAY
E531920/05E 2013 - 04 | Templates | 143

Save: Measurement data list
Figure 138: DIASYS - C:\DIASYS\...- Measurement data list
Save: Bar graphic
TIM-ID: 0000017218 - 001
Figure 139: DIASYS - C:\DIASYS\...- BAR GRAPHIC
144 | Templates | E531920/05E 2013 - 04

Export and import templates
The export or import is always made in the corresponding selection window via the “Export” or “Import”
buttons.
Export/Import templates: Selection of single parameters
Figure 140: SELECT SINGLE PARAMETERS

TIM-ID: 0000017218 - 001
E531920/05E 2013 - 04 | Templates | 145

Import templates: Selection of single parameters
Figure 141: EXPORT TEMPLATES
TIM-ID: 0000017218 - 001
146 | Templates | E531920/05E 2013 - 04

9 Appendix A
9.1 Abbreviations
Abbrevia- Meaning Explanation
tion
ANSI American National Standards Institute Association of American standardization organiza-
tions
ATL Abgasturbolader Exhaust turbocharger
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards ("Deutsche In-
dustrie-Norm")
ISO International Standards Organization International organization for standardization
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LOP Local Operating Panel Control console, control panel
SAE Society of Automotive Engineers U.S. standardization organization
TD Transmitter Deviation Alarm: Sensor comparison fault
TIM-ID: 0000026539 - 001
E531920/05E 2013 - 04 | Appendix A | 147

9.2 Conversion tables
Length
Unit A multiplied by factor = Unit B
in 25.4 = mm
ft 0.3048 =m
yd 0.9144 =m
stat. mile 1.609 = km
nm 1.852 = km
yd 3 = ft
yd 36 = in
Unit B multiplied by factor = Unit A

mm 0.03937 = in
m 3.281 = ft
km 0.6215 = stat. mile
Area
in2 645.16 = mm2
ft2 0.0929 = m2
yd2 0.8361 = m2
stat. mile2 2.5889 = km2
Unit B multiplied by factor Unit A

mm 2 0.00155 = in2
m2 10.7643 = ft2
m2 1.1960 = yd2
km2 0.3863 stat. mile2
Volume
in3 16387 = mm3
ft3 0.02832 = m3
yd3 0.7646 = m3
TIM-ID: 0000020573 - 001
gallon (US) 3.787 = dm3

gallon (brit.) 4.546 = dm3

cm 3 0.06102 = in3
m3 35.31 = ft3
dm3 0.2642 = gallon (US)
dm 3 0.22 = gallon (brit.)
148 | Appendix A | E531920/05E 2013 - 04

Speed
ft/s 0.3048 = m/s
stat. mile/h (mph) 1.609 = km/h
knot (brit.) 1.852 = km/h
Unit B multiplied by factor = Unit B

m/s 3.281 = ft/s
km/h 0.6215 = stat. mile/h (mph)
km/h 0.54 = knot (brit.)
Mass
lb 0.4536 = kg
oz 28.35 =g
ton 1.016 =t

g 0.03527 = oz
kg 2.205 = lb
t 0.9843 = ton
Force
lb 0.4536 = kp
lb 4.4483 =N

kp 2.205 = lb
N 0.101972 = kp
kp 9.80665 =N
Density
lb s /ft
2 4 515.4 = kg/m3

TIM-ID: 0000020573 - 001
kg/m 3 0.00194 = lb s2/ft4
Torque
ft lb 1.3563 = Nm

Nm 0.7373 = ft lb
E531920/05E 2013 - 04 | Appendix A | 149

Pressure
lb/sq in (psi) 703.1 = kp/m2 (mm WS)
lb/sq in (psi) 0.06895 = bar
lb/sq ft 47.883 = Pa
in QS 0.03386 = bar
in QS 345.3 = kp/m2

atm 760 = mm QS
atm 1.0133 = bar
atm 10332 = kp/m2 (mm WS)
atm 1.0332 = kp/cm2 (at)
atm 14.696 = lb/sq in
bar 14.503 = lb/sq in
Mass moment 2nd degree

ft lb s 2 1.3563 = kg m2

kg m 2 0.7373 = ft lb s2
Energy
ft lb 1.356 =J
kcal 4186.8 =J
BTU 1055 =J
CHU 1899 =J

J 0.7376 = ft lb
J 0.0002389 = kcal
J 0.0009479 = BTU
J 0.00052656 = CHU
TIM-ID: 0000020573 - 001
Output
PS 0.7355 = kW
HP 0.7457 = kW
BTU/s 1.055 = kW
kcal/h 1.163 =W
HP 550 = ft lb/s
150 | Appendix A | E531920/05E 2013 - 04

kW 1.36 = PS
kW 1.341 = HP
kW 0.9479 = BTU/s
W 0.8598 = kcal/h
ft lb/s 0.0018 = HP
Temperature
Celsius Kelvin Fahrenheit Réaumur
x °C = x + 273.15 K = 9/5x + 32 °F = (4/5x) °R
xK = x − 273, 15 °C = 9/5(x − 273.15) + 32 °F = 4/5(x − 273.15)
°R
x°F = 5/9(x − 32) °C = 5/9(x − 32) + = 4/9(x − 32) °R
273.15 K
x°R = 5/4x °C = (5/4x) + 273.15 K = (9/4x) + 32 °F
Fuel consumption
mile/gal (US) 0.4251 = km/l
gal/mile (US) 2.3527 = l/km

km/l 2.3527 = mile/gal (US)
l/km 0.4251 = gal/mile (US)
TIM-ID: 0000020573 - 001
E531920/05E 2013 - 04 | Appendix A | 151

9.3 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you – either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact at Headquarters: Service-support@mtu-online.com
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Phone: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 014
152 | Appendix A | E531920/05E 2013 - 04

10 Appendix B
10.1 List of Figures
Figure 1: Dialog box showing online data Figure 43: Triggered start 60
connection 14 Figure 44: Selecting measurement points for data
Figure 2: Dialog box showing offline data recording 61
connection 14 Figure 45: Selecting an active trigger 62
Figure 3: Export window (CSV file) 15 Figure 46: Recorded data 63
Figure 4: Program Info window 16 Figure 47: Save file as 63
Figure 5: Safety notice 16 Figure 48: Opening recorded data 64
Figure 6: User group 17 Figure 49: Selecting measurement points for the
Figure 7: Selecting device 18 y(t) graph 64
Figure 8: Selecting device – device view 18 Figure 50: Offline view of y(t) graph 66
Figure 9: Device description 20 Figure 51: Measurement points list 66
Figure 10: Creating a new device description 21 Figure 52: Absolute scale – Time – Grid 67
Figure 11: Entering engine number 22 Figure 53: Selecting individual parameters 68
Figure 12: Opening a device description 22 Figure 54: Selecting 2D parameters 69
Figure 13: Selecting device description 23 Figure 55: Selecting 3D parameters 70
Figure 14: Selecting device description – with Figure 56: Entering injector code 71
dialog box 24 Figure 57: Comparing PC data and active data 71
Figure 15: Editing device description 25 Figure 58: Comparing PC data and active data 72
Figure 16: Transfer parameter set to central Figure 59: Serial interface driver 73
database 26 Figure 60: Comparison result 73
Figure 17: Retrieve parameter set from central Figure 61: Downloading control unit 74
database 27 Figure 62: Database server prompt to save 75
Figure 18: Schematic diagram of data Figure 63: Online data connection to device 76
management 28 Figure 64: Confirmation prompt for downloading
Figure 19: Transferring parameter set to central new FSW and MPS 76
database 29 Figure 65: Serial interface driver prompt to switch
Figure 20: Retrieving parameter set from central off control unit 77
database 30 Figure 66: Sending FSW to control unit 77
Figure 21: Information on parameter set 31 Figure 67: Data transfer 78
Figure 22: No entries in database server 32 Figure 68: Prompt to switch control unit off and on
Figure 23: Programming CDS/CR control unit 32 again 78
Figure 24: Transferring data on storage medium 33 Figure 69: Receiving control unit data 79
Figure 25: Database server export prompt 34 Figure 70: Programming CDS/CR control unit 79
Figure 26: Delete contents confirmation 34 Figure 71: Log files 80
Figure 27: Transfer data using files – Settings 35 Figure 72: Chronologically ordered error messages 81
Figure 28: Exporting engine data record 36 Figure 73: In chronological order 81
Figure 29: Database server – export successful 37 Figure 74: Activity log 82
Figure 30: DIASYS – File extraction 38 Figure 75: User log file 83
Figure 31: Database server import prompt 39 Figure 76: Device identification 84
Figure 32: Importing engine data record 39 Figure 77: Operating data 86
Figure 33: Database server – import successful 40 Figure 78: Maintenance predictor 87
DCL-ID: 0000017512 - 003
Figure 34: Editing engine data in local database 41 Figure 79: Load profile 89
Figure 35: No entries in database server 42 Figure 80: Load profile context menu 90
Figure 36: Settings 43 Figure 81: Service life matrix 90
Figure 37: Selecting language 44 Figure 82: TBO parameters 91
Figure 38: Selecting language 44 Figure 83: Overview screen 93
Figure 39: Selecting language 45 Figure 84: Exporting an Excel file 94
Figure 40: "Available functions" window showing Figure 85: Hardware key 94
details for ECU 9 46 Figure 86: Alive signal 95
Figure 41: Establish connection to control unit 49 Figure 87: ECU communication 96
Figure 42: "Tools" window showing details for ECU Figure 88: Engine number 97
9 50 Figure 89: Selecting language 98
E531920/05E 2013 - 04 | Appendix B | 153

Figure 90: CCD header 99 Figure 136: DIASYS - C:\DIASYS\... - SINGLE
Figure 91: Leakage map 100 PARAMETER 143
Figure 92: CCS INFO - D:\PROJEKTE\...- Figure 137: DIASYS - C:\DIASYS\...- Y(T) DISPLAY 143
HARDWARE-CCS 101 Figure 138: DIASYS - C:\DIASYS\...- Measurement
Figure 93: CCS INFO - D:\PROJEKTE\... - CCS-TREE 102 data list 144
Figure 94: Edit alarm parameters 102 Figure 139: DIASYS - C:\DIASYS\...- BAR GRAPHIC 144
Figure 95: Input/Output settings – Engine signals 103 Figure 140: SELECT SINGLE PARAMETERS 145
Figure 96: Input/Output settings – System signals 104 Figure 141: EXPORT TEMPLATES 146
Figure 97: Input/Output settings – Analog signals 105
Figure 98: Input/Output settings – Binary signals 106
Figure 99: Parameters 107
Figure 100: Monitoring/Protection module:
protection parameters 107
Figure 101: Monitoring/Protection module:
monitoring parameters 108
Figure 102: Selecting "Reset functions" 110
Figure 103: Warning window 111
Figure 104: DOC and/or DPF selection window 111
Figure 105: Selecting Reset functions 112
Figure 107: Selecting individual parameters 114
Figure 108: Input window for injector replacement
without IIG 118
Figure 109: Input window example: injector A2
replaced 119
with IIG 121
Figure 112: Warning window - 122
Figure 113: Selecting type of operation 122
with IIG 123
Figure 115: Interchanging 2 injectors with one
another 124
Figure 116: IIG deactivated warning window 124
Figure 117: Injector test input/display window 126
Figure 118: Analysis 127
Figure 119: Injector shutdown 128
Figure 120: BDM WITH CABLE 130
Figure 121: BDM - HYPER TERMINAL 131
Figure 122: User group 132
Figure 123: Select device type 132
Figure 124: Device description 133
Figure 125: Creating BDM directory structure 134
Figure 126: Creating PDM directory structure for
PU data (1) 134
DCL-ID: 0000017512 - 003
PU data (2) 135

Figure 128: OPEN 135
PU data (3) 136
Figure 130: Device description 137
Figure 131: BDM programming – Warning 138
Figure 132: Settings for programming by BDM – PU
data 139
Figure 133: Settings for programming by BDM –
GSW 139
Figure 134: BDM programming 140
Figure 135: Completion of BDM programming 141
154 | Appendix B | E531920/05E 2013 - 04

10.2 List of Tables
DCL-ID: 0000017512 - 003
E531920/05E 2013 - 04 | Appendix B | 155

10.3 Index
A R
Abbreviations 147 RCS 53
ADEC-UNI 51 Reset 110, 112
Reset function 110, 112
C Reset functions 109
Calibration Drift Compensation 110, 112
CDC 110, 112 S
CDS 55, 58 Safety notices, standards 12
CDSCR 55, 58 Safety regulations
Contact persons 152 – Auxiliary materials 10
Conversion tables 148 – Environmental protection 10
– Fire prevention 10
D – Fluids and lubricants 10
Device description 20 – Important provisions 4
DOC 110 – Maintenance work 7
Download control unit 74 – Operation 6
DPF 110 – Organizational requirements 5
– Personnel requirements 5
E – Repair work 7
ECS-UNI 51 – Safety notices, standards 12
ECU 4 46 – Startup 6
ECU 7 46 SAM 53
ECU 8 46 Send changed data to control unit 72
ECU 9 46 Sensor 112
EIM 46 Service partners 152
Spare parts service 152
G
General information on the DiaSys program 13 T
Teaching valve limits 114
H
Templates 142
Hotline 152 To menus 85
Tools 93
I
Injector code 71
Injector functions 116
Injector replacement 118, 121
L
Log files 80
M
Maintenance predictor 87
MCS 53
MDEC-C2 46
Measured data 60
DCL-ID: 0000017512 - 003
MTU contact persons 152
O
Operating data 86
P
Parameters 68
Preparations 17
Prepare for BDM programming 130
Programming mode 137
156 | Appendix B | E531920/05E 2013 - 04

Functional Description: Electronic Systems System Description Diasys®

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4 Functions 7 Program MEM

4.1 Overview 46 7.1 Prepare for BDM programming 130

E531920/05E 2013 - 04 | Table of Contents | 3

Unauthorized modifications to the product compromise safety.

4 | General Provisions | E531920/05E 2013 - 04

Working clothes and personal protective equipment

E531920/05E 2013 - 04 | General Provisions | 5

Safety regulations for equipment operation

Malfunctions and emergency stop

Operation of electrical equipment

6 | General Provisions | E531920/05E 2013 - 04

Safety regulations during maintenance and repair work

E531920/05E 2013 - 04 | General Provisions | 7

Safety regulations after completion of maintenance and repair work

Hydraulic installation and removal

Working with batteries

8 | General Provisions | E531920/05E 2013 - 04

Working with laser equipment

E531920/05E 2013 - 04 | General Provisions | 9

Environmental protection and disposal

Auxiliary materials, fluids and lubricants

10 | General Provisions | E531920/05E 2013 - 04

Paints and lacquers

Acids/alkaline solutions/urea solution (AdBlue, DEF)

E531920/05E 2013 - 04 | General Provisions | 11

TIM-ID: 0000040578 - 002

12 | General Provisions | E531920/05E 2013 - 04

Terms and definitions

E531920/05E 2013 - 04 | Introduction | 13

Figure 1: Dialog box showing online data connection

Figure 2: Dialog box showing offline data connection

• contains a range of owner-specific information (refer to chapter “Hardware Key Info”).

Setting the CAN hardware used

14 | Introduction | E531920/05E 2013 - 04

Explanation re Ctrl + Shift + A:

Figure 3: Export window (CSV file)

E531920/05E 2013 - 04 | Introduction | 15

TIM-ID: 0000017205 - 002

Figure 5: Safety notice

16 | Introduction | E531920/05E 2013 - 04

Figure 6: User group

Selecting device type

E531920/05E 2013 - 04 | First Steps | 17

TIM-ID: 0000017206 - 002

Figure 8: Selecting device – device view

18 | First Steps | E531920/05E 2013 - 04

E531920/05E 2013 - 04 | First Steps | 19

Figure 9: Device description

20 | First Steps | E531920/05E 2013 - 04

Create new device description

Figure 10: Creating a new device description

E531920/05E 2013 - 04 | First Steps | 21

Open device description

TIM-ID: 0000017207 - 002

Figure 12: Opening a device description

22 | First Steps | E531920/05E 2013 - 04

Figure 13: Selecting device description

E531920/05E 2013 - 04 | First Steps | 23

TIM-ID: 0000017207 - 002

24 | First Steps | E531920/05E 2013 - 04

Establish connection to central database

Note – ECU-7, ECU-8, ECU-9 and EIM only: