Description

Daewoo D50S-2, D60S-2, D70S-2, G50S-2, G60S-2 2004 Service Manual

You are looking at 866 pages of factory engineering for the Daewoo D50S-2, D60S-2, D70S-2, G50S-2, G60S-2 2004 Service Manual. Not a reprint. Not a compilation of forum guesses. This is the exact document that came off the Daewoo press in November 2004, form number SB4142E00. If you have ever wasted a Saturday because a torque spec you pulled off some website was off by 12 ft-lbs, you already know why you need this. Stop using aftermarket cheat sheets that skip the safety section and give you generic oil weights. This manual gives you the factory torque specifications from page 2 of the document, and it doesn’t stop there.

I have been spinning wrenches since before some of you were born. Twenty-eight years ASE certified, my shop sees six bays full of equipment that should not be treated like a hobby. When a forklift comes in with a blown head gasket, I go straight to the OEM manual because I do not have time to guess. The D50S-2 and its siblings are solid machines, but only if you work on them with the correct data. That is what this manual gives you.

Engine Disassembly and Reassembly Procedures

Section 3 of the manual covers Maintenance, and within that you get the full disassembly sequence. Section 3.1.1 lists major part fixing nuts and bolts. Section 3.1.2 and 3.1.3 cover main structure parts. If you are pulling a cylinder head on a DB58S diesel engine, you need the exact steps from Section 3.1.5. The reassembly is back in Section 3.3, with piston and connecting rod assembly in 3.3.1, cylinder head parts in 3.3.2, and rocker arm and shaft assembly in 3.3.3. Each step is numbered. Each torque value is listed. No guesswork.

Compare that to a generic manual that says “tighten cylinder head bolts to spec” without telling you the sequence or the angle. This manual tells you the sequence. It tells you the angle. It tells you to replace the bolts if they are stretched. Those details are what separate a job that lasts from a job that leaks oil three months later.

Torque Specs and Fluid Capacities

Page 2 of this manual is the Torque Specifications sheet, form SB2004E00 dated December 1998. That is a standalone document included in the manual. It gives you the torque values for bolts, nuts, and studs across the entire machine. Do not reach for a generic torque chart that covers all Japanese engines. The Daewoo DB58S has its own values. The GM Vortec V6 LPG engine (covered in SB2110E01 and SB2111E00) also has specific numbers. You will find injection pump mounting bolts, flywheel bolts, connecting rod cap nuts—all on that page. If you need the V-belt tension, check Section 2.9. Cooling system capacities are in Section 2.8. Fuel requirements are in Section 2.7.3. Oil recommendations are in Section 2.5.1.

Safety Regulations: Not Optional

Section 1.4 is titled Safety Regulations and it is not there to fill paper. Subsection 1.4.2 covers regulations designed to prevent accidents. Subsection 1.4.3 covers damage to engine and premature wear. Subsection 1.4.4 covers pollution. Read them. I have seen techs skip the part about supporting the machine with blocks instead of a hoist. That is how people get crushed. The manual tells you on page 3: “Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands.” That is not a suggestion. That is a written rule from Daewoo.

The manual also covers proper lifting procedures, protective glasses, and welding precautions. If you are a home garage enthusiast, you might think you do not need this because you are careful. You are wrong. Read it. Print it. Tape it to the toolbox.

Commissioning and Operation Procedures

Section 4 of the manual is Commissioning and Operation. This is not just for new machines. If you are doing an engine rebuild, you need the break-in procedure from Section 4.2.1. “Operation of a new engine (Break-In)” tells you exactly how to run the engine for the first 50 hours. It tells you what to check, when to retorque the head, and how to change the oil. Section 4.5 gives you the periodical inspection intervals. Section 4.6 covers cooling system draining and cleaning. Section 4.7 covers valve clearance adjustment. Section 4.8 covers injection timing. Section 4.9 covers tightening the cylinder head. All of this matters if you want the overhaul to last.

Winter operation is covered in Section 4.4, with subsections on antifreeze, excessive cooling, and starting the engine in cold weather. If you operate a forklift in a northern climate, you need that data. If you skip it, you can crack a block.

Does Aftermarket Documentation Compare?

No. I have seen third-party manuals that claim to cover Daewoo forklifts. They leave out the performance curves in Section 1.2. They leave out the engine assembly views for the ECRFA, ECRFB, and ECRFC configurations. They leave out the specific part numbers for the injection nozzle (Section 2.12), the starting motor (Section 2.14), and the air cleaner (Section 2.6). When you need to know the cylinder compression pressure from Section 2.11, a generic manual will not have it. This manual has all of it because it is the original factory document.

If you are working on a D70S-2 or a G50S-2 or any of the models listed, you want the data that came from Daewoo. The manual also includes the separate Safety manual (SB2003E00) and the Torque Specifications sheet. Those two documents alone are worth the price if you do any heavy repair. Do not trust a copy that says “Daewoo compatible.” Trust the original.

Related manuals you might need: DAEWOO Service Manual Contents & Safety Guide, DAEWOO Forklift Service Manual Contents SB4089E00, and DAEWOO Service Manual Contents SB4124E00 Jan. 2004. For background on how engines work, see Internal Combustion Engine and Manual Transmission.

Frequently Asked Questions

Is this manual for the G70S-2 model?

No. The manual covers D50S-2, D60S-2, D70S-2, G50S-2, G60S-2. The G70S-2 is listed but only for two-speed transmission reference.

What engine types are covered in the engine section?

The main engine covered is the Daewoo DB58S diesel engine, which has its own dedicated section (SB4118E00). Additionally, the manual includes data on the HC45 series alternator, starting motors, the G643E Tier II engine, and the GM Vortec V6 (4.3 Liter) LPG engine. The LPG engine has two separate documents: SB2110E01 for the service manual and SB2111E00 for disassembly and assembly. Each engine type has its own specifications for injection timing, valve clearance, compression pressure, and torque values. If you are working on a forklift with a gasoline or LPG conversion, you need those GM Vortec sections. They are not just thrown in; they are factory Daewoo documents with the same format and accuracy as the diesel section.

This is the factory manual for the 2004 Daewoo D50S-2, D60S-2, D70S-2, G50S-2, G60S-2. 866 pages, OEM data, safety regulations, torque specs. Do not guess. Access the Factory Manual.