Hyster H135-155XL (G006 B878) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages (Total): 3056

File Size (Total): 82.70 MB (Speed Download Link)

Brand: Hyster

Model: H135-155XL (G006 B878) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster H135-155XL (G006 B878) Forklift Service Manual

These H135-155XL trucks spend their lives in tough yards and warehouses, moving heavy loads where downtime hurts fast. This service manual is what I’d pull when I need to trace a hard-start diesel, sort out a hydraulic complaint, or rebuild a major component without guesswork. It lays out how the truck is put together and gives you a logical path to inspect, test, and reassemble so everything lines back up and works safely.

Applications & Use Cases

Track engine or fuel issues on the Perkins-powered units by following a step-by-step diagnostic path before you start swapping parts.
Disassemble and rebuild major assemblies—like mast, steer axle, or brake components—while keeping shims, seals, and bearings in the right order.
Verify hydraulic problems by checking pressures, routing hoses correctly, and isolating whether the fault is in the pump, valve, or cylinder.
Adjust linkages and controls so inching, directional control, and lift/lower functions respond smoothly and consistently.
Plan safe maintenance workflow, from blocking and lifting the truck to bleeding systems and confirming repairs with proper functional tests.

FAQ

Q: Can I use this manual on a tablet in the shop?

A: Yes, it’s well-suited for a tablet or laptop so you can zoom diagrams and search quickly while you’re at the truck.

Q: Is this worth printing, or should I keep it digital only?

A: Most techs keep it digital for search, then print key procedures or schematics to mark up and keep next to the machine.

Safety Note

Always support the truck and mast securely and relieve system pressure before loosening any hydraulic or structural components.

📘 Show Index

Hyster H135-155XL (G006 B878) Forklift Index:

toc
- Perkins Diesel Engines
- Safety Precautions Maintenance and Repair
- General
  - General Safety Rules
- Description
  - Engine Serial Number Codes
  - Engine Data
- Engine Removal and Installation
- Cylinder Head Assembly Repair
  - Engine Breather
  - Valve Cover
  - Rocker Arm Assembly
  - Valve Clearance Adjustments
  - Valve Springs
  - Cylinder Head Assembly
  - Valves and Valve Springs
  - Valve Guides
  - Valve Seats
- Piston and Connecting Rod Assemblies Repair
  - General
  - Rod Bearings
  - Piston and Connecting Rod Assembly
  - Piston Cooling Jets
- Crankshaft Assembly Repair
  - General
  - Crankshaft Pulley
  - Rear Oil Seal
  - Crankshaft Flange Wear Sleeve
  - Main Bearings
  - Thrust Washers
  - Crankshaft
  - Crankshaft Timing Ring
  - Flywheel
  - Flywheel Housing
- Timing Case and Timing Gears Repair
  - General
  - Timing Case Cover
  - Front Oil Seal
  - Crankshaft Pulley Wear Sleeve, Install
  - Fuel Pump Gear
  - Idler Gear and Hub
  - Camshaft Gear
  - Crankshaft Gear
  - Timing Case
  - Power Take-Off (PTO) Adaptor
  - Camshaft and Tappets
- Cylinder Block Assembly Repair
  - General
  - Cylinder Block
  - Cylinder Bore
- Engine Timing
  - General
  - How to Set Number One Piston to TDC on Compression Stroke
  - Fuel Injection Pump Timing, Check
  - Fuel Injection Pump Timing, Adjust
- Lubrication System Repair
  - General
  - Oil Filter, Replace
  - Oil Filter Head
  - Oil Sump
  - Oil Pump
  - Oil Strainer and Suction Pipe
  - Relief Valve
  - Dipstick Tube
- Fuel System Repair
  - General
  - Cold Start Advance Unit (KSB)
  - Typical Fuel System
  - Fuel Filter
  - Fuel Injectors
  - Fuel System Air Removal
  - Bosch EVPE Fuel Injection Pump
- Cooling System Repair
  - General
  - Thermostat
  - Coolant Pump
  - Fan
  - Fan Drive
  - Oil Cooler
  - Coolant Bypass Hose
- Electrical Equipment Repair
  - Drive Belt
  - Alternator
  - Starter Motor
  - Starting Aid
  - Pressure Sensor
  - Temperature Sensor
- Engine Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rods
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Engine Block Assembly
  - Lubrication System
  - Fuel System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Torque Specifications
- Special Torque Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rod Assemblies
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Cylinder block
  - Fuel System
  - Lubrication System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Special Tools
- Troubleshooting
tables
- Table 1. Cylinder Head
- Table 2. Valve Guides
- Table 3. Inlet Valves
- Table 4. Exhaust Valves
- Table 5. Valve Springs
- Table 6. Tappets
- Table 7. Rocker Arm Shaft
- Table 8. Rocker Arms and Bushings
- Table 9. Pistons
- Table 10. Piston Rings
- Table 11. Piston Pins
- Table 12. Connecting Rods
- Table 13. Small End Bushings
- Table 14. Connecting Rod Bearings
- Table 15. Piston Cooling Jets
- Table 16. Crankshaft Overhaul Specifications
- Table 17. Maximum Variation (Run-out)
- Table 18. Camshaft
- Table 19. Camshaft Thrust Washer
- Table 20. Camshaft Gear
- Table 21. Gear for Fuel Pump
- Table 22. Crankshaft Gear
- Table 23. Idler Gear and Hub
- Table 24. Timing Gear Backlash Values
- Table 25. Cylinder Block
- Table 26. Oil Pump
- Table 27. Idler Gear for Oil Pump
- Table 28. Relief Valve
- Table 29. Oil Filter
- Table 30. Bosch Fuel Injection Pump
- Table 31. Fuel Injector Settings
- Table 32. Fuel Pump
- Table 33. Fuel Filter
- Table 34. Coolant Pump
- Table 35. Thermostat
- Table 36. Fan Drive Housing
- Table 37. Limits for Flywheel Run Out and Alignment (Total Indic
- Table 38. Alternator
- Table 39. Starter Motor
- Table 40. Starting Aids
- Table 41. List of Possible Causes

toc
- Perkins Diesel Engines
- Safety Precautions Maintenance and Repair
- General
  - General Safety Rules
- Description
  - Engine Serial Number Codes
  - Engine Data
- Engine Removal and Installation
- Cylinder Head Assembly Repair
  - Engine Breather
  - Valve Cover
  - Rocker Arm Assembly
  - Valve Clearance Adjustments
  - Valve Springs
  - Cylinder Head Assembly
  - Valves and Valve Springs
  - Valve Guides
  - Valve Seats
- Piston and Connecting Rod Assemblies Repair
  - General
  - Rod Bearings
  - Piston and Connecting Rod Assembly
  - Piston Cooling Jets
- Crankshaft Assembly Repair
  - General
  - Crankshaft Pulley
  - Rear Oil Seal
  - Crankshaft Flange Wear Sleeve
  - Main Bearings
  - Thrust Washers
  - Crankshaft
  - Crankshaft Timing Ring
  - Flywheel
  - Flywheel Housing
- Timing Case and Timing Gears Repair
  - General
  - Timing Case Cover
  - Front Oil Seal
  - Crankshaft Pulley Wear Sleeve, Install
  - Fuel Pump Gear
  - Idler Gear and Hub
  - Camshaft Gear
  - Crankshaft Gear
  - Timing Case
  - Power Take-Off (PTO) Adaptor
  - Camshaft and Tappets
- Cylinder Block Assembly Repair
  - General
  - Cylinder Block
  - Cylinder Bore
- Engine Timing
  - General
  - How to Set Number One Piston to TDC on Compression Stroke
  - Fuel Injection Pump Timing, Check
  - Fuel Injection Pump Timing, Adjust
- Lubrication System Repair
  - General
  - Oil Filter, Replace
  - Oil Filter Head
  - Oil Sump
  - Oil Pump
  - Oil Strainer and Suction Pipe
  - Relief Valve
  - Dipstick Tube
- Fuel System Repair
  - General
  - Cold Start Advance Unit (KSB)
  - Typical Fuel System
  - Fuel Filter
  - Fuel Injectors
  - Fuel System Air Removal
  - Bosch EVPE Fuel Injection Pump
- Cooling System Repair
  - General
  - Thermostat
  - Coolant Pump
  - Fan
  - Fan Drive
  - Oil Cooler
  - Coolant Bypass Hose
- Electrical Equipment Repair
  - Drive Belt
  - Alternator
  - Starter Motor
  - Starting Aid
  - Pressure Sensor
  - Temperature Sensor
- Engine Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rods
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Engine Block Assembly
  - Lubrication System
  - Fuel System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Torque Specifications
- Special Torque Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rod Assemblies
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Cylinder block
  - Fuel System
  - Lubrication System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Special Tools
- Troubleshooting
tables
- Table 1. Cylinder Head
- Table 2. Valve Guides
- Table 3. Inlet Valves
- Table 4. Exhaust Valves
- Table 5. Valve Springs
- Table 6. Tappets
- Table 7. Rocker Arm Shaft
- Table 8. Rocker Arms and Bushings
- Table 9. Pistons
- Table 10. Piston Rings
- Table 11. Piston Pins
- Table 12. Connecting Rods
- Table 13. Small End Bushings
- Table 14. Connecting Rod Bearings
- Table 15. Piston Cooling Jets
- Table 16. Crankshaft Overhaul Specifications
- Table 17. Maximum Variation (Run-out)
- Table 18. Camshaft
- Table 19. Camshaft Thrust Washer
- Table 20. Camshaft Gear
- Table 21. Gear for Fuel Pump
- Table 22. Crankshaft Gear
- Table 23. Idler Gear and Hub
- Table 24. Timing Gear Backlash Values
- Table 25. Cylinder Block
- Table 26. Oil Pump
- Table 27. Idler Gear for Oil Pump
- Table 28. Relief Valve
- Table 29. Oil Filter
- Table 30. Bosch Fuel Injection Pump
- Table 31. Fuel Injector Settings
- Table 32. Fuel Pump
- Table 33. Fuel Filter
- Table 34. Coolant Pump
- Table 35. Thermostat
- Table 36. Fan Drive Housing
- Table 37. Limits for Flywheel Run Out and Alignment (Total Indic
- Table 38. Alternator
- Table 39. Starter Motor
- Table 40. Starting Aids
- Table 41. List of Possible Causes

toc
- Electronic Control Module (ECM) Diagnostic Troubleshooting
- Safety Precautions Maintenance and Repair
- General
- Description of ECM Based Diagnostics
  - Definition of Terms
  - Diagnostics Overview of the Spectrum Fuel System
  - Malfunction Indicator Lamp (MIL)
  - Spectrum Diagnostic Trouble Codes (DTC)
  - Using a Laptop Computer to Diagnose the Spectrum System
  - Diagnostic Trouble Codes
  - DATA Stream
  - Ignition System Test
  - Injector Test
  - Throttle Test
- On-Board Diagnostics System Check/Malfunction Indicator Lamp
  - Circuit Description
- Preliminary and Intermittent Checks
- GM 3.0L Wiring Schematics and Connectors
- GM 3.0L Diagnostic Trouble Codes
  - DTC 111 – IAT High Voltage Motorola® TMAP
  - DTC 112 – IAT Low Voltage Motorola® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP
  - DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP
  - DTC 115 – Oil Pressure Low
  - DTC 121 – ECT Voltage High
  - DTC 122 – ECT Voltage Low
  - DTC 123 – ECT Higher Than Expected 1
  - DTC 124 – ECT Higher Than Expected 2
  - DTC 131 – MAP High Pressure Motorola® TMAP
  - DTC 132 – MAP Low Voltage Motorola® TMAP
  - DTC 134 – BP High Pressure Motorola® TMAP
  - DTC 135 – BP Low Pressure Motorola® TMAP
  - DTC 142 – Crank Sync Noise
  - DTC 143 – Never Crank Synced At Start
  - DTC 144 – Camshaft Sensor Loss
  - DTC 145 – Camshaft Sensor Noise
  - DTC 211 – Closed Loop Multiplier High (LPG)
  - DTC 212 – HO 2 S Open/Inactive
  - DTC 221 – Closed Loop Multiplier High (Gasoline)
  - DTC 222 – Closed Loop Multiplier Low (Gasoline)
  - DTC 224 – Closed Loop Multiplier Low (LPG)
  - DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
  - DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
  - DTC 243 – Adaptive Learn High (LPG)
  - DTC 244 – Adaptive Learn Low (LPG)
  - DTC 261 – System Voltage High
  - DTC 262 – System Voltage Low
  - DTC 411 – Injector Driver 1 Open
  - DTC 412 – Injector Driver 1 Shorted
  - DTC 511 – COP Failure
  - DTC 512 – Invalid Interrupt
  - DTC 513 – A/D Loss
  - DTC 514 – RTI 1 Loss
  - DTC 515 – Flash Checksum Invalid
  - DTC 516 – Ram Failure
  - DTC 531 – External 5V Ref Lower Than Expected
  - DTC 532 – External 5V Ref Higher Than Expected
  - DTC 555 – RTI 2 Loss
  - DTC 556 – RTI 3 Loss
  - DTC 611 – FPP High Voltage
  - DTC 612 – FPP Low Voltage
  - DTC 631 – TPS1 Signal Voltage High
  - DTC 632 – TPS1 Signal Voltage Low
  - DTC 638 – Throttle Unable To Close
  - DTC 651 – Maximum Govern Speed Override
  - DTC 652 – Fuel Rev Limit
  - DTC 653 – Spark Rev Limit
- GM 4.3L Wiring Schematics and Connectors
- GM 4.3L Diagnostic Trouble Codes
  - DTC 111 – IAT High Voltage Bosch® TMAP
  - DTC 111 – IAT High Voltage Motorola® TMAP
  - DTC 112 – IAT Low Voltage Bosch® TMap
  - DTC 112 – IAT Low Voltage Motorola® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP
  - DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€
  - DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP
  - DTC 115 – Oil Pressure Low
  - DTC 121 – ECT Voltage High
  - DTC 122 – ECT Voltage Low
  - DTC 123 – ECT Higher Than Expected 1
  - DTC 124 – ECT Higher Than Expected 2
  - DTC 131 – MAP High Pressure Bosch® TMAP
  - DTC 131 – MAP High Pressure Motorola® TMAP
  - DTC 132 – MAP Low Voltage Bosch® TMAP
  - DTC 132 – MAP Low Voltage Motorola® TMAP
  - DTC 134 – BP High Pressure Bosch® TMAP
  - DTC 134 – BP High Pressure Motorola® TMAP
  - DTC 135 – BP Low Pressure Bosch® TMAP
  - DTC 135 – BP Low Pressure Motorola® TMAP
  - DTC 142 – Crank Sync Noise
  - DTC 143 – Never Crank Synced At Start
  - DTC 144 – Camshaft Sensor Loss
  - DTC 145 – Camshaft Sensor Noise
  - DTC 211 – Closed Loop Multiplier High (LPG)
  - DTC 212 – HO 2 S Open/Inactive
  - DTC 221 – Closed Loop Multiplier High (Gasoline)
  - DTC 222 – Closed Loop Multiplier Low (Gasoline)
  - DTC 224 – Closed Loop Multiplier Low (LPG)
  - DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
  - DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
  - DTC 243 – Adaptive Learn High (LPG)
  - DTC 244 – Adaptive Learn Low (LPG)
  - DTC 261 – System Voltage High
  - DTC 262 – System Voltage Low
  - DTC 511 – COP Failure
  - DTC 512 – Invalid Interrupt
  - DTC 513 – A/D Loss
  - DTC 514 – RTI 1 Loss
  - DTC 515 – Flash Checksum Invalid
  - DTC 516 – Ram Failure
  - DTC 531 – External 5V Ref Lower Than Expected
  - DTC 532 – External 5V Ref Higher Than Expected
  - DTC 555 – RTI 2 Loss
  - DTC 556 – RTI 3 Loss
  - DTC 611 – FPP High Voltage
  - DTC 612 – FPP Low Voltage
  - DTC 631 – TPS1 Signal Voltage High
  - DTC 632 – TPS1 Signal Voltage Low
  - DTC 638 – Throttle Unable To Close
  - DTC 651 – Maximum Govern Speed Override
  - DTC 652 – Fuel Rev Limit
  - DTC 653 – Spark Rev Limit
- Wire Harness Repair
  - On Vehicle Service Wiring Harness Repair
  - Connectors and Terminals
tables
- Table 1. OBD System Check
- Table 2. Preliminary Checks
- Table 3. Intermittent Checks
- Table 4. Communication Port C002
- Table 5. Coil Connector C003
- Table 6. Fuel System Interface C004
- Table 7. Oil Pressure Connector C005
- Table 8. Distributor Connector C006
- Table 9. Magnetic Pickup Connector C007
- Table 10. Heated Oxygen Sensor C008
- Table 11. Throttle Position Sensor Connector C009
- Table 12. Foot Pedal Position Connector C010
- Table 13. Governor Motor Connector C011
- Table 14. TMAP Connector C012
- Table 15. Starter Solenoid C013
- Table 16. Engine Coolant Temperature C014
- Table 17. Battery Connector C015
- Table 18. Alternator Connection C016
- Table 19. Battery Connector C017
- Table 20. Alternator Connector C018
- Table 21. Instrument Panel Connector C019
- Table 22. Instrument Panel Connector C020
- Table 23. Instrument Panel Connector C021
- Table 24. Fuel Trim Valve Connector C022
- Table 25. Fuel Lockoff Connector C023
- Table 26. Pressure Trim Valve Connector C024
- Table 27. Throttle Body Injector Connector C025
- Table 28. Relay and Fuse Center
- Table 29. DTC 111 – IAT Voltage High (Motorola® TMAP)
- Table 30. DTC 112 – IAT Low Voltage (Motorola® TMAP)
- Table 31. DTC 115 – Oil Pressure Low
- Table 32. Temperature Resistance
- Table 33. DTC 121 – ECT VOLTAGE HIGH
- Table 34. DTC 122 – ECT Voltage Low
- Table 35. DTC 123 – ECT Higher Than Expected 1
- Table 36. DTC 124 – ECT Higher Than Expected 2
- Table 37. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)
- Table 38. DTC 132 – MAP Low Voltage (Motorola® TMAP)
- Table 39. DTC 134 – BP High Pressure (Motorola® TMAP)
- Table 40. DTC 135 – BP Low Pressure (Motorola® TMAP)
- Table 41. DTC 142 – Crank Sync Noise
- Table 42. DTC 143 – Never Crank Synced At Start
- Table 43. DTC 144 – Camshaft Sensor Loss
- Table 44. DTC 145 – Camshaft Sensor Noise
- Table 45. DTC 211 – Closed Loop Multiplier High (LPG)
- Table 46. DTC 212 – HO 2 S Open/Inactive
- Table 47. DTC 221 – Closed Loop Multiplier High (Gasoline)
- Table 48. DTC 222 – Closed Loop Multiplier Low (Gasoline)
- Table 49. DTC 224 – Closed Loop Multiplier Low (LPG)
- Table 50. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
- Table 51. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
- Table 52. DTC 243 – Adaptive Learn High (LPG)
- Table 53. DTC 244 – Adaptive Learn Low (LPG)
- Table 54. DTC 261 – System Voltage High
- Table 55. DTC 262 – System Voltage Low
- Table 56. DTC 411 – Injector Driver 1 Open
- Table 57. DTC 412 – Injector Driver 1 Shorted
- Table 58. DTC 511 – COP Failure
- Table 59. DTC 512 – Invalid Interrupt
- Table 60. DTC 513 – A/D Loss
- Table 61. DTC 514 – RTI 1 Loss
- Table 62. DTC 515 – Flash Checksum Invalid
- Table 63. DTC 516 – Ram Failure
- Table 64. DTC 531 – External 5V Ref Lower Than Expected
- Table 65. DTC 532 – External 5 V Ref Higher Than Expected
- Table 66. DTC 555 – RTI 2 Loss
- Table 67. DTC 556 – RTI 3 Loss
- Table 68. DTC 611 – FPP High Voltage
- Table 69. DTC 612 – FPP Low Voltage
- Table 70. DTC 631 – TPS1 Signal Voltage High
- Table 71. DTC 632 – TPS1 Signal Voltage Low
- Table 72. DTC 638 – Throttle Unable To Close
- Table 73. DTC 651 – Maximum Govern Speed Override
- Table 74. DTC 652 – Fuel Rev Limit
- Table 75. DTC 653 – Spark Rev Limit
- Table 76. Communication Port C002
- Table 77. Injector Connector C003
- Table 78. Injector Connector C004
- Table 79. Oil Pressure Connector C005
- Table 80. Throttle Position Sensor 1 Connector C006
- Table 81. Foot Pedal Position Connector C006A
- Table 82. Coil Connector C007
- Table 83. Module Connector C008
- Table 84. Crank Sensor Connector C009
- Table 85. EGO Sensor Connector C010
- Table 86. Cam Connector C011
- Table 87. Throttle Connector C012
- Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)
- Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)
- Table 90. Starter Solenoid Connector C014
- Table 91. ECT Connector C015
- Table 92. Starter Relay C016
- Table 93. Power Relay C017
- Table 94. Fuel Pump Relay C018
- Table 95. Battery Connector C019
- Table 96. Alternator Connector C020
- Table 97. Alternator Connector C021
- Table 98. Instrument Panel Connector C022
- Table 99. Instrument Panel Connector C023
- Table 100. Instrument Panel Connector C024
- Table 101. Fuel Trim Valve Connector C025
- Table 102. Fuel Lockoff Connector C026
- Table 103. Pressure Trim Valve Connector C027
- Table 104. Injector 1 Connector C028
- Table 105. Injector 2 Connector C029
- Table 106. Injector 3 Connector C030
- Table 107. Injector 4 Connector C031
- Table 108. Injector 5 Connector C032
- Table 109. Injector 6 Connector C033
- Table 110. Relay and Fuse Center
- Table 111. DTC 111 – IAT Voltage High (Bosch® TMAP)
- Table 112. DTC 111 – IAT Voltage High (Motorola® TMAP)
- Table 113. DTC 112 – IAT Low Voltage (Bosch® TMAP)
- Table 114. DTC 112 – IAT Low Voltage (Motorola® TMAP)
- Table 115. DTC 115 – Oil Pressure Low
- Table 116. Temperature Resistance
- Table 117. DTC 121 – ECT VOLTAGE HIGH
- Table 118. DTC 122 – ECT Voltage Low
- Table 119. DTC 123 – ECT Higher Than Expected 1
- Table 120. DTC 124 – ECT Higher Than Expected 2
- Table 121. DTC 131 – MAP High Pressure (Bosch® TMAP)
- Table 122. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)
- Table 123. DTC 132 – MAP Low Voltage (Bosch® TMAP)
- Table 124. DTC 132 – MAP Low Voltage (Motorola® TMAP)
- Table 125. DTC 134 – BP High Pressure (Bosch® TMAP)
- Table 126. DTC 134 – BP High Pressure (Motorola® TMAP)
- Table 127. DTC 135 – BP Low Pressure (Bosch® TMAP)
- Table 128. DTC 135 – BP Low Pressure (Motorola® TMAP)
- Table 129. DTC 142 – Crank Sync Noise
- Table 130. DTC 143 – Never Crank Synced At Start
- Table 131. DTC 144 – Camshaft Sensor Loss
- Table 132. DTC 145 – Camshaft Sensor Noise
- Table 133. DTC 211 – Closed Loop Multiplier High (LPG)
- Table 134. DTC 212 – HO 2 S Open/Inactive
- Table 135. DTC 221 – Closed Loop Multiplier High (Gasoline)
- Table 136. DTC 222 – Closed Loop Multiplier Low (Gasoline)
- Table 137. DTC 224 – Closed Loop Multiplier Low (LPG)
- Table 138. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
- Table 139. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
- Table 140. DTC 243 – Adaptive Learn High (LPG)
- Table 141. DTC 244 – Adaptive Learn Low (LPG)
- Table 142. DTC 261 – System Voltage High
- Table 143. DTC 262 – System Voltage Low
- Table 144. DTC 511 – COP Failure
- Table 145. DTC 512 – Invalid Interrupt
- Table 146. DTC 513 – A/D Loss
- Table 147. DTC 514 – RTI 1 Loss
- Table 148. DTC 515 – Flash Checksum Invalid
- Table 149. DTC 516 – Ram Failure
- Table 150. DTC 531 – External 5V Ref Lower Than Expected
- Table 151. DTC 532 – External 5 V Ref Higher Than Expected
- Table 152. DTC 555 – RTI 2 Loss
- Table 153. DTC 556 – RTI 3 Loss
- Table 154. DTC 611 – FPP High Voltage
- Table 155. DTC 612 – FPP Low Voltage
- Table 156. DTC 631 – TPS1 Signal Voltage High
- Table 157. DTC 632 – TPS1 Signal Voltage Low
- Table 158. DTC 638 – Throttle Unable To Close
- Table 159. DTC 651 – Maximum Govern Speed Override
- Table 160. DTC 652 – Fuel Rev Limit
- Table 161. DTC 653 – Spark Rev Limit

toc
- Electronic Control Module (ECM) Diagnostic Troubleshooting
- Safety Precautions Maintenance and Repair
- General
- Description of ECM Based Diagnostics
  - Definition of Terms
  - Diagnostics Overview of the Spectrum Fuel System
  - Malfunction Indicator Lamp (MIL)
  - Spectrum Diagnostic Trouble Codes (DTC)
  - Using a Laptop Computer to Diagnose the Spectrum System
  - Diagnostic Trouble Codes
  - DATA Stream
  - Ignition System Test
  - Injector Test
  - Throttle Test
- On-Board Diagnostics System Check/Malfunction Indicator Lamp
  - Circuit Description
- Preliminary and Intermittent Checks
- GM 3.0L Wiring Schematics and Connectors
- GM 3.0L Diagnostic Trouble Codes
  - DTC 111 – IAT High Voltage Motorola® TMAP
  - DTC 112 – IAT Low Voltage Motorola® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP
  - DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP
  - DTC 115 – Oil Pressure Low
  - DTC 121 – ECT Voltage High
  - DTC 122 – ECT Voltage Low
  - DTC 123 – ECT Higher Than Expected 1
  - DTC 124 – ECT Higher Than Expected 2
  - DTC 131 – MAP High Pressure Motorola® TMAP
  - DTC 132 – MAP Low Voltage Motorola® TMAP
  - DTC 134 – BP High Pressure Motorola® TMAP
  - DTC 135 – BP Low Pressure Motorola® TMAP
  - DTC 142 – Crank Sync Noise
  - DTC 143 – Never Crank Synced At Start
  - DTC 144 – Camshaft Sensor Loss
  - DTC 145 – Camshaft Sensor Noise
  - DTC 211 – Closed Loop Multiplier High (LPG)
  - DTC 212 – HO 2 S Open/Inactive
  - DTC 221 – Closed Loop Multiplier High (Gasoline)
  - DTC 222 – Closed Loop Multiplier Low (Gasoline)
  - DTC 224 – Closed Loop Multiplier Low (LPG)
  - DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
  - DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
  - DTC 243 – Adaptive Learn High (LPG)
  - DTC 244 – Adaptive Learn Low (LPG)
  - DTC 261 – System Voltage High
  - DTC 262 – System Voltage Low
  - DTC 411 – Injector Driver 1 Open
  - DTC 412 – Injector Driver 1 Shorted
  - DTC 511 – COP Failure
  - DTC 512 – Invalid Interrupt
  - DTC 513 – A/D Loss
  - DTC 514 – RTI 1 Loss
  - DTC 515 – Flash Checksum Invalid
  - DTC 516 – Ram Failure
  - DTC 531 – External 5V Ref Lower Than Expected
  - DTC 532 – External 5V Ref Higher Than Expected
  - DTC 555 – RTI 2 Loss
  - DTC 556 – RTI 3 Loss
  - DTC 611 – FPP High Voltage
  - DTC 612 – FPP Low Voltage
  - DTC 631 – TPS1 Signal Voltage High
  - DTC 632 – TPS1 Signal Voltage Low
  - DTC 638 – Throttle Unable To Close
  - DTC 651 – Maximum Govern Speed Override
  - DTC 652 – Fuel Rev Limit
  - DTC 653 – Spark Rev Limit
- GM 4.3L Wiring Schematics and Connectors
- GM 4.3L Diagnostic Trouble Codes
  - DTC 111 – IAT High Voltage Bosch® TMAP
  - DTC 111 – IAT High Voltage Motorola® TMAP
  - DTC 112 – IAT Low Voltage Bosch® TMap
  - DTC 112 – IAT Low Voltage Motorola® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP
  - DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP
  - DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP€
  - DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP
  - DTC 115 – Oil Pressure Low
  - DTC 121 – ECT Voltage High
  - DTC 122 – ECT Voltage Low
  - DTC 123 – ECT Higher Than Expected 1
  - DTC 124 – ECT Higher Than Expected 2
  - DTC 131 – MAP High Pressure Bosch® TMAP
  - DTC 131 – MAP High Pressure Motorola® TMAP
  - DTC 132 – MAP Low Voltage Bosch® TMAP
  - DTC 132 – MAP Low Voltage Motorola® TMAP
  - DTC 134 – BP High Pressure Bosch® TMAP
  - DTC 134 – BP High Pressure Motorola® TMAP
  - DTC 135 – BP Low Pressure Bosch® TMAP
  - DTC 135 – BP Low Pressure Motorola® TMAP
  - DTC 142 – Crank Sync Noise
  - DTC 143 – Never Crank Synced At Start
  - DTC 144 – Camshaft Sensor Loss
  - DTC 145 – Camshaft Sensor Noise
  - DTC 211 – Closed Loop Multiplier High (LPG)
  - DTC 212 – HO 2 S Open/Inactive
  - DTC 221 – Closed Loop Multiplier High (Gasoline)
  - DTC 222 – Closed Loop Multiplier Low (Gasoline)
  - DTC 224 – Closed Loop Multiplier Low (LPG)
  - DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
  - DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
  - DTC 243 – Adaptive Learn High (LPG)
  - DTC 244 – Adaptive Learn Low (LPG)
  - DTC 261 – System Voltage High
  - DTC 262 – System Voltage Low
  - DTC 511 – COP Failure
  - DTC 512 – Invalid Interrupt
  - DTC 513 – A/D Loss
  - DTC 514 – RTI 1 Loss
  - DTC 515 – Flash Checksum Invalid
  - DTC 516 – Ram Failure
  - DTC 531 – External 5V Ref Lower Than Expected
  - DTC 532 – External 5V Ref Higher Than Expected
  - DTC 555 – RTI 2 Loss
  - DTC 556 – RTI 3 Loss
  - DTC 611 – FPP High Voltage
  - DTC 612 – FPP Low Voltage
  - DTC 631 – TPS1 Signal Voltage High
  - DTC 632 – TPS1 Signal Voltage Low
  - DTC 638 – Throttle Unable To Close
  - DTC 651 – Maximum Govern Speed Override
  - DTC 652 – Fuel Rev Limit
  - DTC 653 – Spark Rev Limit
- Wire Harness Repair
  - On Vehicle Service Wiring Harness Repair
  - Connectors and Terminals
tables
- Table 1. OBD System Check
- Table 2. Preliminary Checks
- Table 3. Intermittent Checks
- Table 4. Communication Port C002
- Table 5. Coil Connector C003
- Table 6. Fuel System Interface C004
- Table 7. Oil Pressure Connector C005
- Table 8. Distributor Connector C006
- Table 9. Magnetic Pickup Connector C007
- Table 10. Heated Oxygen Sensor C008
- Table 11. Throttle Position Sensor Connector C009
- Table 12. Foot Pedal Position Connector C010
- Table 13. Governor Motor Connector C011
- Table 14. TMAP Connector C012
- Table 15. Starter Solenoid C013
- Table 16. Engine Coolant Temperature C014
- Table 17. Battery Connector C015
- Table 18. Alternator Connection C016
- Table 19. Battery Connector C017
- Table 20. Alternator Connector C018
- Table 21. Instrument Panel Connector C019
- Table 22. Instrument Panel Connector C020
- Table 23. Instrument Panel Connector C021
- Table 24. Fuel Trim Valve Connector C022
- Table 25. Fuel Lockoff Connector C023
- Table 26. Pressure Trim Valve Connector C024
- Table 27. Throttle Body Injector Connector C025
- Table 28. Relay and Fuse Center
- Table 29. DTC 111 – IAT Voltage High (Motorola® TMAP)
- Table 30. DTC 112 – IAT Low Voltage (Motorola® TMAP)
- Table 31. DTC 115 – Oil Pressure Low
- Table 32. Temperature Resistance
- Table 33. DTC 121 – ECT VOLTAGE HIGH
- Table 34. DTC 122 – ECT Voltage Low
- Table 35. DTC 123 – ECT Higher Than Expected 1
- Table 36. DTC 124 – ECT Higher Than Expected 2
- Table 37. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)
- Table 38. DTC 132 – MAP Low Voltage (Motorola® TMAP)
- Table 39. DTC 134 – BP High Pressure (Motorola® TMAP)
- Table 40. DTC 135 – BP Low Pressure (Motorola® TMAP)
- Table 41. DTC 142 – Crank Sync Noise
- Table 42. DTC 143 – Never Crank Synced At Start
- Table 43. DTC 144 – Camshaft Sensor Loss
- Table 44. DTC 145 – Camshaft Sensor Noise
- Table 45. DTC 211 – Closed Loop Multiplier High (LPG)
- Table 46. DTC 212 – HO 2 S Open/Inactive
- Table 47. DTC 221 – Closed Loop Multiplier High (Gasoline)
- Table 48. DTC 222 – Closed Loop Multiplier Low (Gasoline)
- Table 49. DTC 224 – Closed Loop Multiplier Low (LPG)
- Table 50. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
- Table 51. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
- Table 52. DTC 243 – Adaptive Learn High (LPG)
- Table 53. DTC 244 – Adaptive Learn Low (LPG)
- Table 54. DTC 261 – System Voltage High
- Table 55. DTC 262 – System Voltage Low
- Table 56. DTC 411 – Injector Driver 1 Open
- Table 57. DTC 412 – Injector Driver 1 Shorted
- Table 58. DTC 511 – COP Failure
- Table 59. DTC 512 – Invalid Interrupt
- Table 60. DTC 513 – A/D Loss
- Table 61. DTC 514 – RTI 1 Loss
- Table 62. DTC 515 – Flash Checksum Invalid
- Table 63. DTC 516 – Ram Failure
- Table 64. DTC 531 – External 5V Ref Lower Than Expected
- Table 65. DTC 532 – External 5 V Ref Higher Than Expected
- Table 66. DTC 555 – RTI 2 Loss
- Table 67. DTC 556 – RTI 3 Loss
- Table 68. DTC 611 – FPP High Voltage
- Table 69. DTC 612 – FPP Low Voltage
- Table 70. DTC 631 – TPS1 Signal Voltage High
- Table 71. DTC 632 – TPS1 Signal Voltage Low
- Table 72. DTC 638 – Throttle Unable To Close
- Table 73. DTC 651 – Maximum Govern Speed Override
- Table 74. DTC 652 – Fuel Rev Limit
- Table 75. DTC 653 – Spark Rev Limit
- Table 76. Communication Port C002
- Table 77. Injector Connector C003
- Table 78. Injector Connector C004
- Table 79. Oil Pressure Connector C005
- Table 80. Throttle Position Sensor 1 Connector C006
- Table 81. Foot Pedal Position Connector C006A
- Table 82. Coil Connector C007
- Table 83. Module Connector C008
- Table 84. Crank Sensor Connector C009
- Table 85. EGO Sensor Connector C010
- Table 86. Cam Connector C011
- Table 87. Throttle Connector C012
- Table 88. Bosch TMAP Connector C013 (Gasoline Fuel System Only)
- Table 89. Motorola TMAP Connector C013 (LPG Fuel System Only)
- Table 90. Starter Solenoid Connector C014
- Table 91. ECT Connector C015
- Table 92. Starter Relay C016
- Table 93. Power Relay C017
- Table 94. Fuel Pump Relay C018
- Table 95. Battery Connector C019
- Table 96. Alternator Connector C020
- Table 97. Alternator Connector C021
- Table 98. Instrument Panel Connector C022
- Table 99. Instrument Panel Connector C023
- Table 100. Instrument Panel Connector C024
- Table 101. Fuel Trim Valve Connector C025
- Table 102. Fuel Lockoff Connector C026
- Table 103. Pressure Trim Valve Connector C027
- Table 104. Injector 1 Connector C028
- Table 105. Injector 2 Connector C029
- Table 106. Injector 3 Connector C030
- Table 107. Injector 4 Connector C031
- Table 108. Injector 5 Connector C032
- Table 109. Injector 6 Connector C033
- Table 110. Relay and Fuse Center
- Table 111. DTC 111 – IAT Voltage High (Bosch® TMAP)
- Table 112. DTC 111 – IAT Voltage High (Motorola® TMAP)
- Table 113. DTC 112 – IAT Low Voltage (Bosch® TMAP)
- Table 114. DTC 112 – IAT Low Voltage (Motorola® TMAP)
- Table 115. DTC 115 – Oil Pressure Low
- Table 116. Temperature Resistance
- Table 117. DTC 121 – ECT VOLTAGE HIGH
- Table 118. DTC 122 – ECT Voltage Low
- Table 119. DTC 123 – ECT Higher Than Expected 1
- Table 120. DTC 124 – ECT Higher Than Expected 2
- Table 121. DTC 131 – MAP High Pressure (Bosch® TMAP)
- Table 122. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)
- Table 123. DTC 132 – MAP Low Voltage (Bosch® TMAP)
- Table 124. DTC 132 – MAP Low Voltage (Motorola® TMAP)
- Table 125. DTC 134 – BP High Pressure (Bosch® TMAP)
- Table 126. DTC 134 – BP High Pressure (Motorola® TMAP)
- Table 127. DTC 135 – BP Low Pressure (Bosch® TMAP)
- Table 128. DTC 135 – BP Low Pressure (Motorola® TMAP)
- Table 129. DTC 142 – Crank Sync Noise
- Table 130. DTC 143 – Never Crank Synced At Start
- Table 131. DTC 144 – Camshaft Sensor Loss
- Table 132. DTC 145 – Camshaft Sensor Noise
- Table 133. DTC 211 – Closed Loop Multiplier High (LPG)
- Table 134. DTC 212 – HO 2 S Open/Inactive
- Table 135. DTC 221 – Closed Loop Multiplier High (Gasoline)
- Table 136. DTC 222 – Closed Loop Multiplier Low (Gasoline)
- Table 137. DTC 224 – Closed Loop Multiplier Low (LPG)
- Table 138. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)
- Table 139. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)
- Table 140. DTC 243 – Adaptive Learn High (LPG)
- Table 141. DTC 244 – Adaptive Learn Low (LPG)
- Table 142. DTC 261 – System Voltage High
- Table 143. DTC 262 – System Voltage Low
- Table 144. DTC 511 – COP Failure
- Table 145. DTC 512 – Invalid Interrupt
- Table 146. DTC 513 – A/D Loss
- Table 147. DTC 514 – RTI 1 Loss
- Table 148. DTC 515 – Flash Checksum Invalid
- Table 149. DTC 516 – Ram Failure
- Table 150. DTC 531 – External 5V Ref Lower Than Expected
- Table 151. DTC 532 – External 5 V Ref Higher Than Expected
- Table 152. DTC 555 – RTI 2 Loss
- Table 153. DTC 556 – RTI 3 Loss
- Table 154. DTC 611 – FPP High Voltage
- Table 155. DTC 612 – FPP Low Voltage
- Table 156. DTC 631 – TPS1 Signal Voltage High
- Table 157. DTC 632 – TPS1 Signal Voltage Low
- Table 158. DTC 638 – Throttle Unable To Close
- Table 159. DTC 651 – Maximum Govern Speed Override
- Table 160. DTC 652 – Fuel Rev Limit
- Table 161. DTC 653 – Spark Rev Limit