Description

Hyster S4.0FT, S5.5FT, H4.0FT, H5.5FT Service Manual

I have been turning wrenches for 28 years. The first thing I check when a manual lands on my bench is whether the specs came from the factory or some aftermarket reprint that guesses torque values. This 82-page Hyster service manual for the Hyster S4.0FT, S5.5FT, H4.0FT, H5.5FT Service Manual models is the real deal. Factory documentation, written for the Kubota 3.8L LPG SI engine that lives under the hood of these lift trucks. If you skip the safety warnings on page 2, you are asking for a trip to the ER. I’ve seen it.

Engine Specifications and Torque Charts

Page 2 tells you to disconnect the battery ground cable before any work – that is the kind of direct instruction you need. After that, the manual dives into engine data: displacement, firing order, compression pressure, and valve lash. The Standard Torque Specification chart and Special Torque Specifications table give you the exact ft-lb values for cylinder head bolts, main bearing caps, and connecting rod nuts. No guessing. No aftermarket approximations. You get factory numbers from Hyster.

Does This Manual Cover the Fuel System?

Yes, there is a dedicated Fuel System Repair section. It does not get into every carburetor adjustment, but it gives you the LPG system service procedures for the Kubota engine. If you need deeper fuel system detail, check the Hyster LPG Fuel System 4.3L Engine Service Manual for the larger engine variant. For this manual, expect fuel line removal, filter change, and component inspection steps backed by the OEM.

Cylinder Head Assembly: Disassembly and Inspection Steps

You get the full sequence: valve covers and ignition coils removal, rocker arm assembly disassembly, valve clearance adjustment, and cylinder head R&I. The manual specifies how to check valve sink, valve seat width, and spring free length. Clean and inspect each part – push rods, rocker arms, valve guides. The install procedure includes tightening order and torque values for the cylinder head bolts. Missing one step here means a leaky head gasket.

Get the Right Oil Pump Clearances

Oil pump rotor clearances are critical. The Lubrication System Repair section spells out the outer rotor outside clearance, outer rotor to inner rotor tip clearance, and side clearance. You need feeler gauges and a straightedge. If the clearances exceed spec, replace the pump. The manual also covers oil pan removal, oil suction tube cleaning, and an oil filter change procedure. Use only the recommended oil viscosity listed in the Engine Data.

7 Key System Sections Documented

This manual breaks down the major systems: Engine Removal and Installation, Cylinder Head Assembly Repair, Timing Gear Case and Timing Gears Repair, Drive Train Camshaft and Cylinder Block Repair, Lubrication System Repair, Cooling System Repair, and Electrical Equipment Repair. Each section follows the same pattern – remove, disassemble, clean and inspect, assemble, install. That structure keeps you from jumping ahead. If you are rebuilding the engine, the Cylinder Block section covers honing and boring, plus cylinder correction for oversize pistons. The camshaft bushing inspection and piston-to-cylinder clearance specs are all there.

Source Authenticity: Factory vs Aftermarket

I have seen aftermarket manuals that list incorrect backlash for the timing gears. This one comes straight from Hyster, part number 4128418, SRM 1893. The torque specs are verified by the OEM. Do not trust a third-party reprint that copies numbers from a 1990s edition. If you are working on the H4.0FT or H5.5FT and need the exact valve clearance adjustment, this is the only document to use. Related manual: Hyster S4.0FT S5.5FT S5.5FTS H4.0FT5 H4.5FT6 Service Manual covers additional model variants. Also see Hyster S4.0, 4.5, 5.5FT, S5.5FTS, S80 2012 Service Manual for earlier year coverage.

For general knowledge on transmission types that might be used with these forklifts, you can read about Manual Transmission basics, but trust me – this manual gives you the specific gear backlash specs for the idler gear and camshaft gear. Another good reference is Manual Transmission theory, but don’t apply generic data to your job.

FAQ

Does this manual cover the Kubota 3.8L LPG engine only?

Yes. All procedures and specs are for that engine in the listed Hyster models.

Does it include the special torque values for the cylinder head and oil pump?

Absolutely. The Special Torque Specifications table lists the exact ft-lb values for critical fasteners. For example, cylinder head bolt torque is given along with the tightening sequence. Oil pump rotor clearance checks are detailed with feeler gauge measurements. Without these factory numbers, you risk snapping bolts or creating leaks. The manual also lists the required special tools – like the valve spring compressor and torque angle gauge – so you can do the job right the first time.

If you are rebuilding a Hyster S4.0FT, S5.5FT, H4.0FT, or H5.5FT, stop guessing and work from the real thing. Access the Factory Manual now and get the OEM data that keeps these lift trucks running.