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FAULT CODE 2191 - Intake Manifold Absolute Pressure Sensor Disagrees with the Compressor Outlet
Pressure Sensor - Condition Exists
Associated Procedures

Cautions and Warnings

CAUTION

To reduce the possibility of damaging a new engine control module (ECM), all other active fault codes must be investigated prior to replacing an ECM.

CAUTION

To reduce the possibility of pin and harness damage, use the following test leads when taking a measurement: Part Number 3164752 - Danfoss™ pressure
sensor breakout cable, Part Number 3824773 - Kavlico™ pressure sensor breakout cable, Part Number 3822758 - male Deutsch™/AMP®/Metri-Pack™ test
lead, and Part Number 3822917 - female Deutsch™/AMP®/Metri-Pack™ test lead.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Check the fault codes.
STEP 1A. Check for an inactive fault code. Fault Code 2191 active?
STEP 1B. Check for multiple active/inactive active fault codes. Fault Codes 153, 154, 155, 263, 265, 354, 355, 488, 546, 547, 783, 1737, 1739, 2427,
2428, 2517, 2518, 2568, 2569, 2799, and/or 2812 active/inactive?
STEP 2. Inspect the air filters for excessive restriction
STEP 2A. Check the engine air filter restriction. Engine air filter restricted?
STEP 2B. Check the engine room or container air inlet filter restriction, if Engine room or container air inlet filter restricted?
installed.
STEP 3. Check the exhaust emissions.
STEP 3A. Measure the exhaust emissions. Exhaust emissions to specification?
STEP 4. Inspect the turbocharger(s).
STEP 4A. Inspect the turbocharger(s) for damage or excessive wear. Turbocharger(s) damaged or out of specification?
STEP 5. Check the exhaust restriction.
STEP 5A. Check the exhaust back pressure. Exhaust back pressure exceeds specification?
STEP 6. Check the aftercooler.
STEP 6A. Check the aftercooler for restriction. Aftercooler core restricted or damaged?

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STEP 7. Clear the fault codes.

STEP 7A. Verify the fault code is inactive. Fault Code 2191 inactive?
STEP 7B. Clear the inactive fault codes. All fault codes cleared?

Guided Step 1 - Check the fault codes.

Guided Step 1A - Check the ECM for active Fault Code 2191.
Conditions

 Connect all components.

 Connect INSITE™ electronic service tool.
 Energize keyswitch circuit.
 Place run/stop/auto switch in STOP mode.

Action

Check for an active fault code.

 Use INSITE™ electronic service tool to read the fault codes.

Fault Code 2191 active?
YES NO
No Repair No Repair
Use the following procedure for an inactive or intermittent fault code. Refer to Procedure
Go to 1B
019-362 in Section 19.

Guided Step 1B - Check the ECM for multiple active fault codes.
Conditions

 Connect all components.

 Connect INSITE™ electronic service tool.
 Energize keyswitch circuit.
 Place run/stop/auto switch in STOP mode.

Action

Check for multiple active fault codes.

 Use INSITE™ electronic service tool to read the fault codes.

Fault Codes 153, 154, 155, 263, 265, 354, 355, 488, 546, 547, 783, 1737, 1739, 2427, 2428, 2517, 2518, 2568, 2569, 2799, and/or 2812 active/inactive?
YES NO
Follow the appropriate troubleshooting steps for the active fault codes or contact a Cummins®

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Authorized Repair Location. No Repair

Reference the appropriate fault code troubleshooting procedure in Section TF. Go to 2A

Guided Step 2 - Inspect the air filters for excessive restriction.

Guided Step 2A - Check the engine air filter restriction.

Conditions

 De-energize keyswitch circuit.

 Place run/stop/auto switch in STOP mode.

Action

Check the engine air filter restriction or damage that may cause excessive restriction.

 Refer to Procedure 010-086 in Section 3.

Engine air filter restricted?
YES NO
A damaged connection has been detected in the sensor or harness connector
No Repair
 Refer to Procedure 010-014 in Section 6.
Go to 7A Go to 2B

Guided Step 2B - Check the engine room or container air inlet filter restriction, if installed.
Conditions

 De-energize keyswitch circuit.

 Place run/stop/auto switch in STOP mode.

NOTE: Only perform Guided Step 2B if engine room or container air inlet filters are installed. If they are not installed proceed to Guided Step 3A

Action

Check the engine room or container air inlet filter restriction or damage that may cause excessive restriction.

 Refer to the original equipment manufacturer (OEM) service manuals for engine room or container air filter restriction specifications and inspection procedures.
Engine room or container air inlet filter restricted?
YES NO
Replace the engine room or container air cleaner elements.
No Repair
 Refer to the OEM service manuals for engine room or container air filter restriction
specifications and inspection procedures.

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Go to 7A Go to 3A

Guided Step 3 - Check the exhaust emissions.

Guided Step 3A - Measure the exhaust emissions.

Conditions

 Energize keyswitch circuit.

 Place run/stop/auto switch in RUN mode, generator circuit breaker closed and rated load applied.

Action

Check that the exhaust emissions are to specification.

 Use an emissions analyser to verify that the engine exhaust emissions are not running too lean.
 Measure the exhaust emissions. Use the following procedure in the QSV81 and QSV91 CM700 Generator Set Troubleshooting and Repair Manual, Bulletin 4021314. Refer to Procedure 014-011
in Section 14.
 Compare the measured exhaust emissions to the engines emissions specification. Use the following procedure in the QSV81 and QSV91 CM700 Generator Set Troubleshooting and Repair
Manual, Bulletin 4021314. Refer to Procedure 018-016 in Section V.
Exhaust emissions to specification?
YES NO
Correct the exhaust emissions.
No Repair
 Use INSITE™ electronic service tool to tune the exhaust emissions.

Go to 4A Go to 7A

Guided Step 4 - Inspect the turbocharger(s).

Guided Step 4A - Inspect the turbocharger(s) for damage or excessive wear.

Conditions

 De-energize keyswitch circuit.

 Place run/stop/auto switch in STOP mode.

Action

Check the turbocharger radial bearing clearance, axial bearing clearance and impeller for damage or out-of-specification condition.

 Check the turbocharger axial clearance. Use the following procedure in the QSV81 and QSV91 CM700 Generator Set Operation and Maintenance Manual, Bulletin 4021313. Refer to Procedure
010-038 in Section 8.

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 Check the turbocharger radial clearance. Use the following procedure in the QSV81 and QSV91 CM700 Generator Set Operation and Maintenance Manual, Bulletin 4021313. Refer to Procedure
010-047 in Section 8.
Turbocharger(s) damaged or out of specification?
YES NO
Replace the turbocharger(s).
No Repair
 Use the following procedure in the QSV81 and QSV91 CM700 Generator Set Troubleshooting
and Repair Manual, Bulletin 4021314. Refer to Procedure 010-033 in Section 10.
Go to 7A Go to 5A

Guided Step 5 - Check the exhaust restriction.

Guided Step 5A - Check the exhaust back pressure.

Conditions

 Energize keyswitch circuit.

 Place run/stop/auto switch in RUN mode, generator circuit breaker closed and rated load applied.

Action

Check that the exhaust back pressure specification is not exceeded.

 Measure the exhaust back pressure. Use the following procedure in the QSV81 and QSV91 CM700 Generator Set Troubleshooting and Repair Manual, Bulletin 4021314. Refer to Procedure 011-
009 in Section 11.
Exhaust back pressure exceeds specification?
YES NO
Inspect the exhaust system and associated components and remove restriction.

 Refer to the OEM service manual.

No Repair
Replace the exhaust system components causing the restriction.

 Refer to the OEM service manual.

Go to 7A Go to 6A

Guided Step 6 - Check the aftercooler.

Guided Step 6A - Check the aftercooler for restriction.

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Conditions

 De-energize keyswitch circuit.

 Place run/stop/auto switch in STOP mode.

Action

Check that the aftercooler core is not restricted or damaged.

 Inspect the aftercooler core. Use the following procedure in the QSV81 and QSV91 CM700 Generator Set Troubleshooting and Repair Manual, Bulletin 4021314. Refer to Procedure 010-001 in
Section 10.
Aftercooler core restricted or damaged?
YES NO
Clean or replace the aftercooler core.

No Repair  Clean or replace the aftercooler core. use the following procedure in the QSV81 and QSV91
CM700 Generator Set Troubleshooting and Repair Manual, Bulletin 4021314. Refer to
Procedure 010-001 in Section 10.
Go to 7A Go to 7A

Guided Step 7 - Clear the fault codes.

Guided Step 7A - Disable the fault code.

Conditions

 Connect all components.

 Connect INSITE™ electronic service tool.

Action

Clear the fault codes.

 Use INSITE™ electronic service tool to verify that Fault Code 2191 is inactive.
Fault Code 2191 inactive?
YES NO
Return to troubleshooting steps or contact a Cummins® Authorized Repair Location if all steps have
No Repair
been completed and checked.
Go to 7B Go to 1A

Guided Step 7B - Clear the inactive fault codes.

Conditions

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 Energize keyswitch circuit.

 Place run/stop/auto switch in STOP mode.
 Connect all components.
 Connect INSITE™ electronic service tool.

Action

Clear the inactive fault codes.

 Use INSITE™ electronic service tool to clear the inactive fault codes.
All fault codes cleared?
YES NO
No Repair Troubleshoot any remaining active fault codes.
Repair complete Appropriate troubleshooting chart

Last Modified: 05-Aug-2013

Copyright © 2000-2010 Cummins Inc. All rights reserved.

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