Description

Doosan D35S-5, D40S-5, D45S-5, D50C-5, D55C-5 2007 Service Manual

If you’ve wasted hours chasing a Doosan forklift’s stumbling idle because some aftermarket manual had the injection timing wrong, you know the cost of bad information. This 2007 Service Manual for the D35S-5, D40S-5, D45S-5, D50C-5, and D55C-5 with the 5.8 Liter DB58S diesel engine is the factory document — 152 pages of procedures and specs that the dealer uses. No guesswork. It covers the 3-speed and 2-speed transmission variants listed on page 1. I’ve seen too many DIY guys snap head bolts because they trusted a third-party chart. This is the original OEM print from Doosan, scanned from the actual binder.

Engine Overhaul: What the 5.8 Liter DB58S Covers

Page 1 lists all models: D35S-5, D40S-5, D45S-5, D50C-5, D55C-5 plus the D50S-5, D60S-5, D70S-5, D80S-5, D90S-5 with 3-speed, and the 2-speed variants. The manual focuses on the DB58S diesel — a 5.8 liter that’s been in thousands of industrial trucks. You get the factory breakdown for cylinder head removal, piston ring gaps, valve clearance adjustments, and the exact sequence for torquing the main bearing caps. Each step includes the required tool list. For example, the injection pump timing procedure calls for a dial indicator with a 10 mm stem. No skipping.

7 Critical Safety Warnings You Cannot Skip

Page 3 opens with the WARNING symbol — a triangle with an exclamation. It tells you: improper operation, lubrication, maintenance, or repair can cause injury or death. The manual explicitly states that if you use a tool or method not recommended by Doosan, you must verify it’s safe. I’ve seen guys ignore that and drop a load on their foot. The safety section covers lifting procedures, fire prevention, and battery handling. Each subsequent chapter repeats specific warnings where hazards exist. You don’t get that in a $20 PDF from some third-party site.

Torque Specs That Match the Assembly Line

Head bolts, intake manifold, flywheel, injection nozzle holder — every fastener has a foot-pound value that Doosan approved. The manual gives the torque sequence for the cylinder head in two stages: first to 58 ft-lb, then an additional 90-degree turn. That detail is why engines don’t leak. The same rigor applies to the transmission housing bolts and the axle flange nuts. If you’re rebuilding a D55C-5, you need those numbers. Aftermarket manuals often round them off or copy from a different engine. Don’t trust that.

Foreword: Page 5 Tells You How to Use This Manual

Doosan says this manual is for customers and distributors who want to gain basic knowledge. It’s not a novel — you start with the trouble code, go to the diagnostic procedure, then the repair. Page 5 is the foreword. It explains the manual’s structure: specifications first, then disassembly, inspection, reassembly. Each section includes illustrations with callouts. The manual also warns that specs and torques can change — so check with a dealer for updated bulletins. That’s real-world advice, not legal filler.

Does This Manual Cover the Fuel System and Transmission?

Yes. The service manual includes the entire fuel system — injection pump, injectors, governor, and the fuel filter housing. For the transmission, it covers the clutch pack clearance and shift fork adjustment on both the 3-speed and 2-speed units. If you need to rebuild the Manual Transmission in a D50C-5, the shift rail removal sequence is in here. The manual also includes the hydraulic system for the power steering and mast lift circuits. For basic operation and daily checks, you’ll want the Doosan Lift Trucks Operation & Maintenance Manual alongside it — that one covers fluid capacities and lube intervals.

Who Should Use This Manual: Not Just Factory Techs

Home garage guys who own a D45S-5 and need to replace the water pump. Fleet owners with a mixed lot of D35S-5 and D55C-5 machines. Independent repair shops that don’t have dealer access. This manual assumes you know how to use a torque wrench and a micrometer — it doesn’t teach basic mechanic skills. But it gives you the factory sequence and the critical clearances. For example, the valve seat runout limit is 0.002 in. That’s not something you guess. You need that number.

Source Validity: OEM Print vs Aftermarket Copies

Every page in this manual was printed by Doosan in 2007 — SB4118E01 is the part number. The safety information, torque tables, and wiring diagrams are all original. Aftermarket manuals often reprint older versions with missing pages or blurred diagrams. This is a direct scan of the physical binder — 152 pages, no watermarks, no reprints. If you’ve been burned by a manual that didn’t include the correct Doosan D35S-5 Technical Manual 2007 | 46 Pages for the transmission, you know the difference. This one is complete.

For those who want the full technical data including all specifications and adjustments without the step-by-step repair procedures, there’s also the Doosan D35S-5, D40S-5, D45S-5, D50C-5, D55C-5 2007 Technical Manual — that one is 46 pages and focuses on specs and troubleshooting. The service manual here is the one you remove the cylinder head by.

Another external reference: if you’re unfamiliar with how a Manual Transmission works internally, a quick read on Wikipedia helps before you start pulling gears. But for the actual rebuild, stick to this manual.

Frequently Asked Questions

Does this manual cover the D50S-5 and D60S-5 models listed on page 1?

Yes. Page 1 includes D50S-5, D60S-5, D70S-5, D80S-5, D90S-5 in both 3-speed and 2-speed versions. The engine and chassis content applies to those models as well.

Do I need any tools beyond standard hand tools to follow this manual?

The manual calls out specialty tools like a dial indicator, torque angle gauge, and a Doosan injection pump timing pin. For most disassembly, standard 3/8 and 1/2 inch sockets and wrenches work. You’ll also need a hydraulic press for piston pin removal. Don’t start without reading the required tool list at the beginning of each section.

If you’re tired of chasing bad torque specs and incomplete wiring diagrams, get the factory data. Click below to access the Factory Manual — the same one Doosan dealers use. Your D35S-5 or D55C-5 will run right the first time.