Complete service repair manual with electrical wiring diagrams for Hyster H150-275H, P150-200B (C007) Forklifts Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster H150-275H, P150-200B (C007) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 765 pages
File Format: PDF
Language: English
Section
Part No.
SRM Number Rev Date
FRAME
910051
0100 SRM 0141
10/88
PERKINS DIESEL ENGINES 6.3544, T6.3544
910054
0600 SRM 0007
05/97
GM ENGINE V8-350 (5.7L)
599805
0600 SRM 0104
09/93
COOLING SYSTEM
897934
0700 SRM 0626
11/01
TWO-BARREL CARBURETOR
910058
0900 SRM 0012
03/97
LPG FUEL SYSTEM
910060
0900 SRM 0016
03/97
WEBER CARBURETOR WITH GOVERNOR
897128
0900 SRM 0347
12/92
OIL CLUTCH and JET PUMP
910062
1200 SRM 0022
02/97
THREE-SPEED PS TRANS – DESCR / OPER
899661
1300 SRM 0033
03/97
FIVE-SPEED MANUAL TRANSMISSION
910066
1300 SRM 0039
10/87
SPEED REDUCER
910068
1300 SRM 0044
01/97
THREE-SPEED PS TRANSMISSION – REPAIR
910070
1300 SRM 0142
04/83
DIFFERENTIAL
910072
1400 SRM 0046
11/03
PLANETARY GEAR AXLE
910030
1400 SRM 0047
11/03
DRIVE AXLE
910073
1400 SRM 0049
09/03
DRIVE AXLE
910076
1600 SRM 0054
10/03
STEERING AXLE
910031
1600 SRM 0071
07/97
BRAKE SYSTEM (AIR)
910084
1800 SRM 0083
10/95
BRAKE SYSTEM (HYDRAULIC)
910085
1800 SRM 0084
10/81
PARKING BRAKE
910088
1800 SRM 0146
06/87
AIR COMPRESSOR
910089
1800 SRM 0150
08/87
HYDRAULIC GEAR PUMPS
910091
1900 SRM 0097
10/03
FLOW CONTROL VALVE
910093
1900 SRM 0147
02/79
MAIN CONTROL VALVE (PARKER)
910098
2000 SRM 0099
02/97
MAIN CONTROL VALVE (HUSCO)
910099
2000 SRM 0100
02/97
TILT CONTROL VALVE
910101
2100 SRM 0102
07/94
TILT CYLINDERS
910102
2100 SRM 0103
10/03
ALTERNATOR
899784
2200 SRM 0002
10/03
STARTER
910107
2200 SRM 0106
02/01
HIGH ENERGY IGNITION SYSTEM
899788
2200 SRM 0107
03/02
INSTRUMENT PANEL INDICATORS and SENDERS
910110
2200 SRM 0143
12/03
ELECTRICAL WARNING DEVICES
910111
2200 SRM 0144
05/97
ELECTRICAL SYSTEM TROUBLESHOOTING
899793
2200 SRM 0153
07/97
UPRIGHT
910117
4000 SRM 0127
09/84
PULPWOOD LOADER
910122
5000 SRM 0154
04/79
DIAGRAMS
910138
8000 SRM 0148
01/79
PERIODIC MAINTENANCE
910140
8000 SRM 0151
04/87
CAPACITIES and SPECIFICATIONS
910141
8000 SRM 0152
01/82
PART NO. 599795
Rev. 12/03
hyster-599805-09-93-srm0104…3
Cooling System…47
Safety Precautions Maintenance and Repair…48
General…51
Description…52
Radiator…52
Radiator Cap…52
Thermostat…52
Water Pump…53
Fan and Fan Shroud…53
Cooling System Checks…53
Radiator…53
Thermostat…53
Water Pump…54
Exhaust Leaks…54
Fan and Fan Shroud…54
Radiator Cleaning…54
Drain…54
Clean…54
Fill…55
Troubleshooting…56
hyster-899784-10-03-srm0002…91
toc…91
Alternator with Regulator…91
Safety Precautions Maintenance and Repair…92
General…95
Description…95
Alternator Repair…97
Alternator Type A…97
Remove and Disassemble…97
Clean…98
Assemble…99
Install…99
Alternator Type B…102
Remove and Disassemble…102
Clean…102
Assemble…103
Install…104
General Check and Adjustment…105
Low Output Check (Type A or Type B)…105
High Output Check (Type A or Type B)…107
Brushes Circuit Check…108
Delco Alternators…108
Motorola Alternators…109
Diodes Check…110
Diode Bridge Check…110
Delco and Leece-Neville Alternators…110
Motorola Alternators…110
Rotor Field Winding Check…111
Stator Windings Check…112
Voltage Regulator Check…112
Troubleshooting…112
hyster-899788-03-02-srm0107…117
toc…117
High Energy Ignition (HEI) System…117
Safety Precautions Maintenance and Repair…118
Description…121
Distributor Repair…123
Remove…123
Disassemble…123
Assemble…128
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…129
Install, If Crankshaft WAS Rotated when Distributor was Removed…129
Ignition Coil Replacement…130
Some Four- and Six-Cylinder Models…130
Remove…130
Install…131
V8, Some Four- and Six-Cylinder Models…131
Remove…131
Install…132
Electronic Module Replacement…133
Remove…133
Install…133
Sensing Coil Replacement…134
Remove…134
Install…134
Spark Plugs Replacement…134
Remove…134
Install…135
Visual Check…135
High Voltage Wires Check…135
Ignition Coil Check…136
Coil in Distributor Cap Design…136
Separate Coil Design…136
Sensing Coil, Check…137
Electronic Module Check…137
Ignition Timing Adjustment…137
GM V8-366 (6-liter) Ignition System Check…139
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …139
Specifications…139
Troubleshooting…140
hyster-910030-11-03-srm0047…209
toc…209
Planetary Gear Axle…209
Safety Precautions Maintenance and Repair…210
General…213
Description…213
Operation…214
Planetary Gear Axle Repair…215
Remove…215
Disassemble…215
Planetary Axle, Disassemble…218
Assemble and Install…222
Planetary Axle, Assemble…223
Torque Specifications…228
Troubleshooting…231
tables…209
Table 1. Axle-to-Frame Fasteners…222
Table 2. Standard Torque Values for Axle Fasteners…228
Table 3. Drive Wheel Nut Torque…228
Differential…407
Safety Precautions Maintenance and Repair…408
General…411
Description…411
Differential Repair…411
Remove…411
Differential Carrier From Axle Housing, Remove…411
Differential and Ring Gear From Differential Carrier, Remove…415
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…417
Disassemble…418
Differential and Ring Gear Assembly, Disassemble…418
Drive Pinion and Pinion Carrier, Disassemble…420
Clean and Inspect…422
Assemble…423
Pinion, Bearings, and Pinion Carrier, Assemble…423
Pinion Bearings, Adjust Preload…424
Press Method…424
Yoke or Flange Method…424
Triple-Lip Seal, Install…425
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…426
Differential and Ring Gear, Assemble…428
Differential Gears Rotating Torque, Check…431
Differential and Ring Gear Assembly, Install…432
Differential Bearings, Preload Adjust…433
Ring Gear, Runout Check…434
Ring Gear Backlash, Adjust…434
Gear Set, Tooth Contact Pattern Check…436
Thrust Screw, Install and Adjust…438
Install…439
Differential Assembly Into Axle Housing, Install…439
Specifications…441
Troubleshooting…445
tables…407
Table 1. Ring Gear Backlash Adjustment Specifications…435
Table 2. Ring and Pinion Tooth Contact Adjustment…437
Table 3. General Specifications…441
Table 4. Rivet Installation Pressure…441
Table 5. Pinion Adjustment…441
Table 6. Pinion Preload Pressure…442
Table 7. Torque Specifications…443
Table 8. Torque Specifications for Metric Hardware…444
Table 9. Torque Specifications for Metric (Fine) Hardware…444
hyster-910073-09-03-srm0049…449
toc…449
Drive Axle…449
Safety Precautions Maintenance and Repair…450
General…453
Description…453
Drive Axle Repair…454
Disassemble (Type 1 Shown)…454
Clean…457
Inspect…457
Assemble (Type 1 Shown)…458
Torque Specifications…461
Troubleshooting…462
Steering Control Unit…465
Safety Precautions Maintenance and Repair…466
General…469
Description…469
Operation…469
Steering Wheel and Column Assembly Repair…471
Steering Column Assembly Repair…471
Type A Steering Column Assembly…471
Remove and Disassemble…471
Assemble and Install…473
Type B Steering Column Assembly…475
Remove and Disassemble…475
Assemble and Install…475
Steering Control Unit…478
Disassemble…478
Clean…481
Assemble…482
System Air Removal…487
Troubleshooting…487
Hydraulic Gear Pumps…543
Safety Precautions Maintenance and Repair…544
Description…547
Operation…548
Flow Control Valve…548
Relief Valve…549
Hydraulic Gear Pump Repair…549
Remove…549
Disassemble…550
Clean…550
Inspect…551
Assemble…554
Install…556
Pump Output Check…556
Method No. 1…556
Method No. 2…557
Hydraulic System Air Check…558
Tilt Cylinders…609
Safety Precautions Maintenance and Repair…610
General…613
Description…613
Tilt Cylinder Repair…613
Remove…613
Disassemble…613
Clean…613
Assemble…614
Tilt Cylinders With O-Ring or Single-Lip Seals…614
Tilt Cylinders for XM and XMS Models…615
Tilt Cylinders for H700-800A and Early Model H700-920B…616
Install…617
Tilt Cylinders Using Chevron Packing…618
Install…619
Tilt Cylinder Leak Check…621
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…622
Torque Specifications…623
Piston Rod Nut…623
Retainer…624
Troubleshooting…626
tables…609
Table 1. Movement Rates (Maximum) for Tilt Cylinders…622
Starter…629
Safety Precautions Maintenance and Repair…630
General…633
Description and Operation…633
Starter Repair…635
Remove…635
Disassemble…635
Clean…636
Assemble…636
Install…637
General Checks and Adjustments…637
Troubleshooting…640
Instrument Panel Indicators and Senders…645
Safety Precautions Maintenance and Repair…646
General…649
Description…650
Steering Column Gauges, Meters, and Indicators…650
LED Display Panel…650
Battery Discharge Indicators…650
Brush Wear Indicators…657
Motor Temperature Indicators…657
LX Series Display Panel…659
Hourmeter Functions…659
Battery Indicator Function…660
Status Code Function…661
ZX Series Display Panels…661
Display Panel…661
Basic Display Panels…661
Performance Display…664
Brush Wear Indicators…667
Adjustments – General…668
Replacement – General Information…668
Meter Replacement…669
Sender Replacement…670
Fuel Level Sender…670
Pressure and Temperature Sender…670
ITW Display Panel Replacement…671
Remove…671
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…672
Remove…672
Display Panel Assembly, Replace…672
Indicator LEDs…673
Battery Indicators…673
Digital Display (Performance Display Panel Only)…673
Status Code or Performance Level Switches and Indicator LEDs (Pe…673
Basic Display Panel, Replace Parts…673
Performance Display Panel, Replace Parts…675
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…676
Remove and Replace…676
Specifications…676
Meter Specifications…676
Sender Specifications…677
Troubleshooting…677
Meter…677
Hyster H150-275H, P150-200B (C007) Repair Service Manual