Description

Daewoo D35S-2, D40S-2, D45S-2, D40SC-2, D45SC-2 2004 Service Manual – OEM Shop Specs for the Workbench

You’re staring at a Daewoo D35S-2 with a dead alternator, or maybe a D45S-2 that won’t hold oil pressure. Without the factory service manual, you’re guessing on torque values and hoping the wiring diagram matches reality. That costs hours and parts. This 870-page factory manual from 2004 covers the D35S-2, D40S-2, D45S-2, D40SC-2, and D45SC-2. It’s the same binder the dealer techs had. No aftermarket shortcuts, no reprints. Every torque spec, every clearance, every diagnostic tree comes from Daewoo’s engineering department.

Engine Overhaul: Disassembly and Reassembly (Sections 2.2 and 2.4)

The manual walks you through pulling the DB58 diesel or GM Vortec V6 gasoline engine. Section 2.2 lists the order for removing external parts – intake manifold, exhaust, injection lines. Step-by-step, with torque callouts. When you get to reassembly in Section 2.4, the bolt tightening sequence for the cylinder head is right there. Need the main bearing cap torque? It’s in the spec tables, not buried in a paragraph. You don’t guess – you torque to the number Daewoo stamped on the print.

Torque Specifications: Page 2 of the Manual

Flip to page 2 and you’ll find the torque spec sheet. Engine assembly bolts, flywheel housing, front gear cover – all in ft-lbs. No conversion needed. The manual also includes a separate Torque Specifications form (SB2004E00) that lists fastener tightening values for the entire machine. If you’re bolting up an oil pan or an alternator bracket, you have the number right there. This is why you don’t use generic spec sheets – factory gives you the exact grade and thread pattern.

Fuel System: Injection Nozzle and Injection Pump (Sections 5.3 and 5.4)

Diesel injection pumps are finicky. Section 5.4 covers the injection pump removal and timing procedures for the DB58 engine. The manual tells you the required tools – including a dial indicator and adapter – and gives the static timing specs in degrees. Section 5.3 shows how to bench-test the injection nozzles, including opening pressure. If you’ve ever had a D40S-2 that smokes at idle, that information alone saves you from swapping parts blind.

Alternator and Starting Motor Diagnostics (Sections SB2134E00 and SB2135E00)

Electrical gremlins in a forklift? The manual dedicates separate chapters to the alternator and starting motor. For the HC45 alternator, you get the Alternator Output Test and Machine Test procedures – including load specs. For the starting motor, there’s an Off Machine No Load Test and a full component test sequence. If you don’t have factory amp draw and resistance values, you’re shooting in the dark. This manual gives you the targets.

Who Needs This Manual and Why

If you run a shop that services material handling equipment, you already know the cost of a wrong torque value on a cylinder head. Home garage enthusiasts working on a D35S-2 or D45SC-2 will find the safety warnings in the opening pages – proper lifting procedures, blocking protocols, personal protective equipment. The manual doesn’t assume you know the machine. It starts with lifting points and maximum component weights. Beginners get the same cautionary details a pro would see, plus the troubleshooting flowcharts in Section 6: Cause of Trouble, Diagnosis and Troubleshooting.

Source Authenticity: OEM vs. Aftermarket Documentation

Every aftermarket manual I’ve seen fudges the torque table or leaves out the lubrication system oil flow diagram. This copy is a direct scan of the Daewoo factory publication, form numbers SB2200E00 through SB2110E00. The 870 pages include the original safety decal warnings, the engine specification tables for both diesel and gasoline models, and the System Operations section that explains how the velocity governor works. You aren’t reading a condensed version – you’re reading what the service department used when the forklift was new. That matters when you’re disassembling a transmission or adjusting the LP converter.

Does this manual cover the fuel injection pump on the DB58 diesel?

Yes. Section 5.4 covers injection pump removal, installation, and timing. Includes static timing specs and required tool list.

What about electrical system diagnostics for the alternator and starting motor?

The manual contains separate chapters for the alternator (SB2134E00) and starting motor (SB2135E00). For the HC45 alternator you get output test procedures, machine test steps, and troubleshooting problem lists. The starting motor chapter includes no-load test specs, component tests, and a full disassembly/assembly sequence. Factory test voltages and current draws are given – not generic values. You can verify a stator winding or a solenoid pull-in coil with those numbers.

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If you need to understand the basics of how an Internal Combustion Engine works before diving into the manual, that link covers the theory. For transmission-specific work, the Manual Transmission article details the gear train fundamentals. But this manual gives you the Daewoo numbers – the ones that keep the forklift running in your shop. Access the Factory Manual.