Hyster-Yale C007 H150H, H165H, H180H, H200HS, H200H, H225H, H250H, H275H, P150B, P200B Forklift Service Manual Collection (P/N 899788)

These component publications combine truck-specific specifications and diagrams with service sections used across several Hyster models. Match the engine, transmission, axle and component revision before selecting a procedure or replacement part.

Engine coverage: The GM publication includes both engine sizes named above; the truck specification tables identify the GM V8-350 for this family. Detroit 4-53N material covers specifications, maintenance references and wiring, without a dedicated internal engine overhaul chapter. The GM chapter refers engine removal and installation to model-specific frame instructions rather than reproducing those procedures.

PDF Search, Navigation and Page Count

Search and diagram detail: Much of the service text is searchable, but some illustrated procedures, tables and circuit pages have little or no searchable text. Text search in Gauges is unreliable because of its character encoding. Embedded bookmarks are present in 35 files; Specification Tables and Flow Control Valve have none. Small electrical labels require zooming, and some lettering in the Hydraulic System Schematic remains faint or broken when enlarged.

The ZIP contains 37 printable PDF files totaling 531 pages, including seven original cover sheets, one contents page, two notes pages and one blank page. The table above lists each publication’s complete PDF page count.

Engine, Drivetrain and Lift-System Service

The following is a selection of covered work, rather than a complete contents list. Other material includes fuel- and hydraulic-tank service and cab-window material specifications.

• Engine and fuel systems: Perkins and GM internal repair, injection timing and bleeding, HEI diagnosis, Weber and two-barrel carburetor service, LPG components and cooling-system checks.
• Transmission repair: Five-speed gearbox and synchronizer work, torque-converter and powershift overhaul, MONOTROL and inching controls, pressure testing and linkage adjustment.
• Axles and differential: Drive-axle hubs and seals, oil clutch and jet pump, speed reducer, transfer case, bearing preload, pinion-depth shimming and tooth-contact checks.
• Hydraulics and steering: Single- and tandem-gear-pump repair, output testing, main and two-speed lift valves, flow and tilt valves, cylinder resealing and steering-unit service.
• Upright and attachments: Mast, carriage, lift-cylinder and fork procedures, chain adjustment, roller shimming, laydown-tilt arrangements and rigid or rotating pulpwood loaders.
• Brakes and electrical diagnosis: Air and hydraulic brake repair, compressor and governor service, parking brakes, symptom-based electrical charts, starter and alternator tests.

This collection is suited to experienced lift-truck service personnel with pressure-test equipment, electrical test instruments and lifting equipment appropriate for the assemblies being handled.

Perkins and GM Engine Work

The Perkins section provides step-by-step procedures for cylinder-head and valve work, rocker gear, oil-pump service, timing gears, crankshaft, pistons, connecting rods, cylinder liners and water-pump repair. T6.3544 material also addresses the turbocharger, piston-cooling jets and oil cooler.

Injection-pump and injector coverage includes removal, installation, timing, bleeding and checks. Internal servicing requires specialist equipment; the timing procedures identify tool 8108.

The GM section covers cylinder heads, valve guides and seats, hydraulic lifters, timing chain and camshaft, crankshaft bearings, piston assemblies and coolant-pump work. Fuel-system sections distinguish gasoline carburetors from the LPG vaporizer/regulator, filter and shut-off valve arrangements.

Transmission and Final-Drive Detail

The five-speed publication separates the range transmission from the forward/reverse gearbox and includes a six-sheet assembly sequence. Powershift material explains the compound planetary ranges, clutch packs, pump, sump, filter, oil coolers and control valve, alongside overhaul procedures and stall-speed checks.

MONOTROL, inching and range-linkage information connects control operation with the pressure-test locations and hydraulic-flow diagrams. This supports diagnosis of engagement problems before internal transmission work is planned.

Differential procedures cover pinion-bearing preload, shim selection, gear clearance and tooth-contact patterns. For H150–275H trucks, the replacement-pinion warning identifies thicker spacer P/N 125277 to prevent thread damage or a loose nut; another caution explains how cold ring-gear installation can damage the case half and cause excessive runout.

Hydraulics, Steering and Mast

Pump inspection distinguishes wear, contamination and cavitation, with output checks using either a flow meter or a timed-volume method. Housing and bearing-block positions, seal orientation and relief-setting checks after pump replacement receive specific attention because incorrect assembly or excessive pressure can damage the pump or hydraulic system.

Main-control-valve sections address lift and tilt spools, two-speed operation, relief and check valves. Steering material covers axle and hub service, cylinder repair, steering control-unit timing and air removal.

Upright procedures extend through carriage and lift-cylinder work, fork handling, chain adjustment, side- and back-roller shimming and operational checks. The laydown-tilt section describes the special equipment and transport-clearance considerations for lowering and raising the upright. Separate pulpwood-loader material distinguishes rigid and rotating booms.

Brake Revisions and Component Service

Air-brake coverage includes chambers, drums, shoes, control valve, compressor and governor. Hydraulic-brake material addresses the MICO valve, actuator, two-stage master cylinder, wheel cylinders, bleeding, pedal adjustment and relief checks; the mechanical parking brake has its own publication.

Brake valves 270512, 270987, 308588 and 308599 are distinguished by first-use serial numbers and repair-kit arrangements. Revised valve 308599 can be fitted to earlier trucks with the specified spring hardware. Cleaning cautions explain how petroleum products can damage hydraulic-brake rubber parts and contaminate linings.

Electrical Fault Tracing and Drawings

The 13 symptom-based charts address dead-system, no-crank, solenoid, slow-cranking, crank/no-start, battery-drain, charging, gauge, horn and powershift-engagement faults.

Drawings include the H150–275H/P150–200B Gasoline & LPG Electrical Schematic, its matching Diesel Electrical Schematic, the Hydraulic System Schematic, Powershift Transmission hydraulic-flow diagrams, Instrument Panel Electrical Connections and the Engine Cabling Diagram. Cab and heater wiring is also included.

Starter and alternator sections add voltage-drop, regulator, diode, armature and field-coil tests with internal repair information. HEI module testing references Kent-Moore tester J-24642. Gauge and sender material focuses on checks and replacement rather than internal rebuilding.

Maintenance and Workshop References

The maintenance publication combines inspection and lubrication schedules with procedures for filters, fluids, brakes, forks, chains, tires and wheel bearings. Fastener references cover metric and inch thread identification, strength markings and general tightening practices; component sections provide their own torque tables, wear limits and adjustment data.

Safety material addresses mast blocking, battery and fuel isolation, stored hydraulic and air pressure, brake-lining dust and handling heavy drivetrain assemblies.

Examples of Injector-Seal and Transmission Test Data

Perkins injector-seat washer thickness differs between engines: 2.03 mm (0.080 in) for the 6.3544 and 0.71 mm (0.028 in) for the T6.3544. The engine section identifies these as distinct sealing parts.

The T13 pressure-check table lists pump-port control pressure of 105–115 psi at 1500 rpm in neutral, alongside a converter-outlet setting of 18–22 psi under the same stated speed and selector condition.