Hyster-Yale C007 H150H, H165H, H180H, H200HS, H200H, H225H, H250H, H275H, P150B, P200B Forklift Service Manual (P/N 2200 SRM 107, 2200 SRM 2)

• Covers Hyster H150H, H165H, H180H, H200HS, H200H, H225H, H250H, H275H, P150B, and P200B trucks in the 15,000- to 27,500-lb class, including gasoline/LPG and diesel configurations, standard five-speed and T13 powershift transmissions, and hypoid or planetary drive-axle applications.
• Documents Perkins 6.3544/T6.3544 and GM 4.3L/5.7L engine repair, HEI ignition, Weber and two-barrel carburetors, LPG fuel-system service, injection-pump timing, fuel-system bleeding, cooling-system checks, and related troubleshooting.
• Addresses five-speed gearbox and synchronizer repair, torque-converter and powershift overhaul, MONOTROL and inching controls, pressure testing, control-valve service, range-linkage adjustment, transfer case, drive axle, and differential setup.
• Details gear-pump inspection and output testing, main and two-speed hydraulic control valves, flow and tilt control valves, tilt cylinders, steering axle and steering control unit, plus upright, carriage, lift-cylinder, chain, roller, and pulpwood-loader service.
• Includes air and hydraulic service-brake repair, air-compressor and governor work, MICO brake-valve and hydraulic-actuator service, master- and wheel-cylinder overhaul, brake bleeding and adjustment, and parking-brake procedures.
• Provides 13 symptom-based electrical diagnostic charts plus model-specific gasoline/LPG and diesel schematics, starter and alternator repair, HEI test procedures, gauge and sender checks, instrument-panel connections, engine cabling, and cab/heater wiring.
• The set contains 37 PDF files totaling 531 pages, with identified Hyster publications including P/N 899784 / 2200 SRM 2, P/N 897934 / 700 SRM 626, P/N 910072 / 1400 SRM 46, P/N 899788 / 2200 SRM 107, P/N 910442 / 8000 SRM 231, P/N 910102 / 2100 SRM 103, and P/N 910107 / 2200 SRM 106.

Component Coverage and Documentation

The model tables connect the North American designations to H7.00H through H12.50H, including H9.00HS, and P7.00B/P9.00B. They separate GM V8-350 gasoline/LPG, Perkins 6.3544 diesel, and Detroit Diesel 4-53N applications, along with standard-transmission, powershift, hypoid-axle, and planetary-axle builds. Several SRM sections are multi-model Hyster publications; the applicable H150-275H and P150-200B trucks are identified in their model lists, tables, figures, or schematics.

The Perkins section reaches into cylinder-head and valve work, rocker gear, lubrication components, crankshaft, pistons and connecting rods, injection pump and injectors, water pump, turbocharger service on T6.3544 engines, engine removal, internal assembly, timing, bleeding, checks, and troubleshooting. The included GM publication covers 4.3L V6 and 5.7L V8 engine service, while the truck specification sheets identify the GM V8-350 for this family. Detroit 4-53N coverage is limited to truck specifications, maintenance references, wiring, and related driveline checks; a full internal Detroit engine overhaul chapter is not included.

Both transmission configurations receive repair-level treatment. The five-speed section covers the range transmission, forward/reverse gearbox, synchronizer inspection, disassembly, and a six-sheet assembly sequence. T13 powershift coverage includes the torque converter, clutch packs, compound planetary ranges, pump, filter, oil coolers, control valve, MONOTROL pedal, inching system, pressure-test locations, linkage adjustment, stall-speed checks, and hydraulic-flow diagrams. Separate sections address the speed reducer and transfer case, oil-clutch assembly and jet pump, drive-axle hubs and seals, and differential bearing preload, pinion-depth shimming, gear clearance, and tooth-contact inspection.

Hydraulic and mast material includes single- and tandem-gear-pump repair and flow testing, lift and tilt spools, two-speed lift-valve operation, relief and check valves, steering-flow control, tilt-cylinder resealing, steering-axle and hub repair, and steering control-unit timing. Upright coverage extends to the carriage, lift cylinder, forks, chain adjustment, side- and back-roller shimming, and final checks. A separate section handles rigid and rotating pulpwood-loader arrangements.

The brake files cover air chambers, drums, shoes, the air-brake control valve, compressor and governor, MICO hydraulic brake valve, actuator, two-stage master cylinder, wheel cylinders, bleeding, relief checks, pedal adjustment, and the mechanical parking brake. They distinguish brake valves 270512, 270987, and 308588 used before serial numbers C7A 2150B, C7P 3649A, and C7S 1599B from revised valve 308599, including retrofit hardware for earlier trucks. The drive-axle section also records a seal change beginning at C7A-2267B, C7P-4034B, and C7S-1632C.

Technical Preview and Specifications

Notable drawings include the H150-275H/P150-200B Gasoline & LPG Electrical Schematic, the matching Diesel Electrical Schematic, the Hydraulic System Schematic, Powershift Transmission hydraulic-flow diagrams, Instrument Panel Electrical Connections, and the Engine Cabling Diagram. The electrical charts isolate dead-system, no-crank, solenoid, slow-cranking, crank/no-start, battery-drain, charging, gauge, horn, and powershift-engagement faults. Starter and alternator sections add exploded views, voltage-drop testing, regulator and diode diagnosis, armature and field-coil checks, and internal repair data.

Specifications cover component torque, transmission and hydraulic pressure tests, cooling and lubricant capacities, brake-fluid requirements, electrical test values, wear limits, bearing preload, gear clearance, and adjustment data. The five-page file 8000152 links models and configurations to engine, transmission, axle, hydraulic, upright, tire, wheel, capacity, T13 pressure-check, and special-torque tables. A separate fastener publication covers metric and inch thread identification, strength markings, and general tightening practices.

The repair cautions are unusually specific. On H150-275H differentials, the washer supplied with a replacement pinion must not be used; the manual specifies thicker Hyster spacer P/N 125277 to avoid damaged threads or a loose pinion nut. The differential section also warns that installing the ring gear cold can damage the case half and create excessive runout. Gear-pump housings and bearing blocks must return to their marked positions, and a relief setting left too high after pump replacement can damage the hydraulic system. Petroleum-based cleaners can damage hydraulic-brake rubber parts and linings. Specialist-tool references include Perkins injection-pump timing tool P/N 8108 and Kent-Moore tester J-24642 for the HEI module.

Before repair work on the mast, brakes, hydraulic circuits, LPG system, or heavy drivetrain assemblies, lower and block the upright, isolate the battery and fuel supply, release stored hydraulic or air pressure, avoid compressed-air cleaning of brake linings, and use lifting equipment rated for the component.

PDF Set and Page Breakdown

• Engine, fuel, cooling, and drivetrain — 228 pages: Engine and Fuel System, 40; GM 4.3L V6 and 5.7L V8 Engines, 23; High Energy Ignition, 25; LPG Fuel System, 17; Gasoline Carburetor, 11; Two-Barrel Carburetor, 5; Cooling System, 7; Five-Speed Transmission, 13; Torque Converter and Transmission, 28; Transmission, 28; Oil Clutch Assembly and Jet Pump, 5; Speed Reducer and Transfer Case, 2; Differential, 18; Drive Axles, 6.
• Hydraulics, steering, mast, and attachment — 92 pages: Gear Pumps, 12; Main Control Valve sections, 8 and 7; Flow Control Valve, 2; Tilt Control Valve, 5; Tilt Cylinders, 15; Steering Axle, 8; Steering Housing and Steering Control Unit, 14; Upright Assembly, 16; Pulpwood Loaders, 5.
• Brakes and chassis — 42 pages: Air Compressor, 6; Air Brake System, 8; Hydraulic Brake System, 17; Parking Brake Assembly, 3; Frame, 8.
• Electrical, maintenance, and reference — 169 pages: Alternator with Regulator, 20; Starter, 11; Electrical Schematic and diagnostic charts, 57; Hydraulic/electrical diagrams, 9; Gauges, 23; Maintenance Schedule, 35; Metric and Inch Fasteners, 9; specification file 8000152, 5.