Hyster H135FT, S5.5FTS, H80, S6.0FT, H6.0FT 2012 Service Manual

Description

You have a Hyster S4.0, 4.5, 5.5FT, S5.5FTS, or S80 lift truck with a fuel system problem. Without the Hyster S4.0, 4.5, 5.5FT, S5.5FTS, S80 2012 Service Manual, you’re working blind. This 52-page OEM document from Hyster covers the GM 4.3L GFI fuel setup – throttle body, injectors, ECU, exhaust. Page 1 lays out the scope. Aftermarket versions skip details. This one doesn’t.

Gasoline Fuel System: Factory Procedures for GM 4.3L

The manual opens with the gasoline fuel system chapter for the GM 4.3L engine equipped with GFI (gas fuel injection). It covers Hyster 4.3L V-6 Engine Service Manual as a related document if you need deeper engine work. Within this section you get the Fuel System Repair procedures – Before Repair, After Repair, Fuel Leakage Checks for lift trucks built before and after January 2010, Fuel Line Pressure Check, and Fuel Injector Repair (remove and install). Page 2 has the safety warnings you must read first.

Safety Precautions Maintenance and Repair: Not Optional

Page 2 of this manual is where Hyster lists the life-saving rules. Disconnect the battery connector on internal combustion lift trucks before any work. Always use correct blocks to prevent rolling. Wear safety glasses. Use lifting mechanisms for heavy parts. Make sure slings, chains, cables are correctly fastened and the crane capacity is enough. Use only HYSTER APPROVED parts – aftermarket parts that don’t meet OEM specs are a liability. Fasten a DO NOT OPERATE tag when repairing. Gasoline, LPG, CNG, and diesel are flammable; batteries generate flammable gas during charging. Keep fire and sparks away and ventilate the area. These are not suggestions. This manual includes WARNING and CAUTION notes throughout.

Electronic Throttle Body Repair: Remove, Clean/Inspect, Install

The electronic throttle body section gives three steps. First, removal procedure – likely involving disconnecting harness and fuel lines. Second, clean and inspect the throttle bore and plate. Third, install with correct gaskets and torque. The manual specifies the order. If you skip the cleaning step, you might chase an idle issue later.

Get the Fuel Leakage Check Right for Your Build Date

Hyster split the fuel leakage check procedures based on when the lift truck was built – before or after January 2010. Use the wrong one and you might miss a critical check point. The manual gives distinct steps for each. Also includes Fuel Line Pressure Check and injector removal/installation. For the exact torque values on injector hold-downs, you need the manual – I’m not going to guess them here.

5 Truck Model Groups Covered for Exhaust Repair

The exhaust system chapter covers five distinct model groups: S4.0, 4.5, 5.5FT, S5.5FTS (and S80 variants); H4.0FT5/FT6; H6.0FT, H7.0FT; S6.0FT, S7.0FT. Each group has separate removal, inspection, and installation procedures for pre- and post-January 2010 builds. Oxygen sensor removal and install is also covered. This level of detail is why you need the OEM manual.

Does the Manual Cover ECU Removal for Pre-2010 and Post-2010 Trucks?

Yes. The Control System section includes Electronic Control Unit (ECU) removal and installation procedures for both build date ranges. Don’t mix them up – the wiring and bracket locations changed. The manual gives the exact steps for each. For related documentation, see the Hyster LPG Fuel System 4.3L Engine Service Manual if your truck runs LPG instead of gasoline.

OEM Documentation vs. Aftermarket: Why It Matters

This manual is a genuine Hyster publication, part number 1624738, 900 SRM 1244. It’s not a third-party reprint. The 52 pages are scanned from the original factory document. Every torque spec, every fuel line routing, every ECU pinout comes from Hyster’s engineering team. If you’re tempted to use a generic manual, remember that a wrong fuel pressure spec can cause a leak or engine damage. I’ve seen too many comebacks from aftermarket data. Stick with the OEM source. If you need a parts breakdown, the Hyster H70-H110XL Parts Catalog 1999 covers older models separately.

For reference on other vehicle systems, see also Manual Transmission and Manual Transmission – but those are different applications entirely.

Frequently Asked Questions

Is this manual for both pre-2010 and post-2010 lift trucks?

Yes, the manual provides separate procedures for each build date throughout the fuel system, ECU, and exhaust chapters.

Does it include the oxygen sensor replacement?

Yes.

What safety warnings must I follow when working on the fuel system?

Disconnect the battery connector before any maintenance. Use lifting mechanisms for heavy parts. Always use correct blocks to prevent the unit from rolling or falling. Wear safety glasses. Use only HYSTER APPROVED parts. Follow all WARNING and CAUTION notes in the instructions. Gasoline, LPG, CNG, and diesel are flammable – keep sparks away and ventilate the area. Batteries generate flammable gas during charging. Fasten a DO NOT OPERATE tag to the controls when making repairs. Make sure slings, chains, and cables are correctly fastened and the crane capacity is sufficient. Keep the work area clean and use the correct tools. These are direct quotes from page 2 of the manual, and ignoring them can result in serious injury or death.

Can I use this manual for a Hyster H4.0FT?

The manual covers H4.0FT5/FT6 models in the exhaust system section, but the primary focus is on the S-series models listed. Check page 1 for the complete model list to confirm coverage.

You need the exact factory specs for your Hyster S4.0, 4.5, 5.5FT, S5.5FTS, or S80. Don’t trust generic PDFs from random sites. Access the Factory Manual from AutoRepairManuals and get the 52 pages of OEM procedures that will keep your lift truck running safely and correctly.