Description

Hyster H4.0FT5, H4.5FTS5, H4.0FT6, H4.5FT6, H5.0FT Service Manual – 110 Pages of Factory Specs

You roll a Hyster into the bay, customer says it’s smoking and losing power. You pop the hood, see a Kubota 3.8L diesel, and reach for the manual. If you grab a third-party reprint, good luck – you’ll get a blurry diagram and a torque value that’s close but not right. That’s how you snap head bolts. This Hyster H4.0FT5, H4.5FTS5, H4.0FT6, H4.5FT6, H5.0FT Service Manual is the OEM print with Part No. 4047206, SRM 1557. No guesswork. The factory says what it says, and you follow it.

Cylinder Head Assembly: Where the Manual Earns Its Keep

Section 3 of this manual, Cylinder Head Assembly Repair, is where you live if you’re chasing compression issues. It walks you through valve covers, fuel injectors, rocker arm assembly, valve clearance adjustments, and the full cylinder head teardown. The procedure for removing valves and valve springs is laid out step by step. Each sub-section – Remove, Disassemble, Clean and Inspect, Assemble, Install – forces you to check parts you’d otherwise skip. The manual gives you the specs for valve sink, valve seat width, and spring free length. No aftermarket reprint has this detail. I’ve seen guys skip the valve guide inspection and end up with a bent pushrod three weeks later. Don’t be that guy.

Does This Manual Cover the Fuel System?

Yes, it does – Section 6, Fuel System Repair. Fuel injectors (remove, inspect, clean, replace, install, test) and the fuel injection pump (remove, clean, inspect, install). If you’re dealing with a hard-start or low-power complaint on an H4.0FT6, you need the factory test procedure for the injectors. The manual lists the test steps – not just a generic “check spray pattern” but the specific Hyster-approved method. And it tells you which fuel lines to tag before removal. I’ve had customers bring me machines where a previous tech swapped injectors without cleaning the lines. That’s a fire hazard. This manual shows you the clean and inspect step before install.

3 Systems You Can’t Afford to Guess On

First: the timing gear case and timing gears. Section 4 covers removal, inspection, and installation of the crankshaft gear, idler gear, and camshaft gear. Backlash specs for each gear are in the Engine Specifications section. Second: the drive train, camshaft, and cylinder block repair – Section 5. Honing and boring, cylinder correction (oversize), piston ring gap, connecting rod alignment. Third: the lubrication system – Section 7. Oil pump clearances (outer rotor outside clearance, tip clearance, side clearance, rotor shaft clearance). If any of those clearances are out, the oil pressure drops, and you’re rebuilding the bottom end. The manual gives you the numbers. Use them.

Engine Removal and Installation: Factory Procedure

Section 2 is a short but critical section. Engine removal and installation – no fluff, just the steps for pulling the Kubota 3.8L out of the chassis. You’ll need a lifting mechanism; the manual says so. It lists the required tool list implicitly by referencing the special tools at the back. Before you disconnect anything, tag all wiring and hoses. The safety notes on page 2 tell you to disconnect the battery ground cable on internal combustion lift trucks. I’ve seen technicians ignore that and arc a wrench across the starter terminal. That’s how you get a fire. Follow the manual.

Torque Specs and Fluid Capacities

Don’t trust your memory on head bolt torque. The Special Torque Specifications section and the Standard Torque Chart are in the back of the manual. Whatever fastener you’re tightening – cylinder head bolts, connecting rod nuts, flywheel bolts – the value is there. Page 73 for the charge pressure on the oil pump? Actually, the torque specs are all in the Engine Specifications chapter near the end. Use a calibrated torque wrench, not a beam-style you dropped last week. The manual also includes engine oil pressure specs, oil filter cross-reference, and cooling system capacities. It’s all factory data from Hyster, not a third-party guess.

FAQ

Can I use this manual for the H5.5FT or S6.0FT models?

This manual covers H4.0FT5, H4.5FTS5, H4.0FT6, H4.5FT6, H5.0FT – and also includes data for H5.5FT (H80-120FT) and S6.0FT, S7.0FT (S135-155FT) per the table of contents. The engine data tables list specifications for both R005/S005/U005 and F024/G024 variants. So yes, for those models the relevant engine specs are here, but the chassis-specific torque values may differ – check the Special Torque Specifications section.

Is this a genuine OEM manual?

Yes. Part No. 4047206, SRM 1557, published by Hyster Company.

You’re not here to read about theory. You’re here to fix a forklift. This manual puts the factory procedure in your hands – the same one Hyster dealers use. It’s 110 pages of Kubota 3.8L diesel engine repair, from the crankcase to the injectors. No filler. If you’ve got a H4.0FT5, H4.5FTS5, H4.0FT6, H4.5FT6, or H5.0FT in your shop, get the right documentation. Don’t rely on a PDF that was scanned from a copy of a copy. Access the Factory Manual and torque everything to spec the first time.

• Hyster LPG Fuel System 4.3L Engine Service Manual
• Hyster Service Manual 8000 SRM 1409
• HYSTER Forklift Service Manual 0600 SRM 1961
• Manual Transmission – for reference on drivetrain concepts, though this manual covers the engine only.
• Manual Transmission – same link, used for context on gear train alignment.