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Pub.No.00EMT0043, DECEMBER 2014 
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Pub.No.00EMT0043, DECEMBER 2014 
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GROUP INDEX 
General Information 
Product Information 
Table of Contents 
1. Technical Specification ........... 1-1 
2. Engine....................................... 2-1 
3. Clutch........................................ 3-1 
4. G-85 Transmission................... 4-1 
5. Propeller Shaft ......................... 5-1 
6. Front Axle ................................. 6-1 
7. Rear Axle .................................. 7-1 
8. Wheels and Tyres .................... 8-1 
9. Suspension .............................. 9-1 
10. Brakes..................................... 10-1 
11. Steering ...................................11-1 
12. Frame ...................................... 12-1 
13. Cabin....................................... 13-1 
14. HVAC....................................... 14-1 
15. Electricals............................... 15-1 
Periodic Maintenance Schedule 
FOREWORD 
This Shop Manual is published for the information and 
guidance of personnel responsible for maintenance of 
FUSO FI series truck, and includes procedures for adjust- 
ment and maintenance services. 
We earnestly look forward to seeing that this manual is 
made full use of in order to perform correct services with 
no wastage. 
For more details, please consult your nearest authorized 
FUSO dealer or distributors. 
Kindly note that the specifications and maintenance ser- 
vice figures are subject to change without prior notice in 
line with improvement which will be effected from time to 
time in the future. 
DECEMBER 2014 
Applicable models 
FIV1PFX2L 
FIV1PHX2L 
Shop Manual 
(FIV1P) 
©2014 FUSO Truck & Bus Corporation 
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5 Maintenance Section 
1 
Shop Manual - General 
Information 
General Information 
Introduction 
This workshop manual is designed to assist 
technicians to repair and maintain FUSO vehicles. 
Even before when a technician proceed to repair or 
maintain the vehicle or any of the aggregate it is 
important to know safety related aspects and 
information to perform the activity. This section of 
service manual provides an insight about various 
safety signs used and general information on 
removal and installation, disassembly and 
assembly, inspection, adjustment and trouble 
shooting. 
Important Instructions 
Individuals who undertake repairs should have 
essential skills or training. Any repairs related to 
safety or critical items such as the steering, 
brakes, suspension or the supplementary restraint 
system should be carried out by a FUSO dealer/ 
certified technician only. Following correct service 
methods and repair procedures are essential for 
the safe, reliable operation of all motor vehicles as 
well as the personal safety of the individual while 
carrying out the work. This manual cannot 
possibly predict all such variations and offer 
warnings or cautions as to each. Deviation from 
the instructions provided in this manual could 
lead to personal injury or damage to the vehicle. 
The danger, warning, caution and notice are 
included wherever it is required. Anyone using the 
service procedures or tools must make sure that 
neither personal safety nor vehicle safety is 
compromised. 
Illustration Callout and Indicator 
Line 
Callouts and Indicator lines are inserted into an 
illustration, when some details or part needs to be 
emphasized with action. 
Contents in the manual 
This manual contains the procedures for 
performing the required service operations. The 
procedures are separated into the following 
important topics. 
Model and Serial Descriptions 
Technical Specification 
Construction Details 
Notice 
"NOTICE" is used to highlight information 
that are important to the technician to properly 
complete the service procedure. 
CAUTION 
"CAUTION" used with safety alert symbol 
indicates a potentially hazardous situation 
which if not avoided may result in minor or 
moderate injury. 
WARNING 
"WARNING" indicates a potentially hazardous 
situation which if not avoided could result in 
death or serious injury. 
1 
Nm 
DICV-CL-0358A 
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2 
Shop Manual - General 
Information 
Working Principle 
Work tools Information 
Troubleshooting 
Service Procedure 
Periodic Maintenance Schedule 
Model and Serial Descriptions 
This topic discusses the Model Number Description 
of each aggregate and location of the serial number 
on the aggregate and its description. 
Technical Specification 
This section gives the technical specification of the 
system/component. 
Construction Details 
This topic discusses the material, construction 
details and the fitment layout of an aggregate. 
Working Principle 
Working principle of an aggregate is discussed in 
this topic. 
Troubleshooting Chart 
Trouble shooting chart list downs the symptom of 
complaints, its probable cause and the corrective 
actions. 
Work Tools Information 
The work tools information lists down the tools 
used to repair an aggregate. 
Service Procedure 
Removal and Installation 
This section gives information on removal and 
refitment of components from a vehicle. 
Disassembly and Assembly 
This section gives information on disassembling 
and assembling a component and/or a system, 
wherever applicable. 
Torque Specification 
This section gives the torque values applicable to 
the specified components while tightening them, 
wherever applicable. 
Periodic Maintenance Schedule 
This topic lists down the various service check 
points for an aggregate and the frequency at which 
it needs to be serviced. 
Workshop Tools and Equipment 
It is essential that all tools and equipment are 
maintained in good condition. Never use tools or 
equipment for any purpose other than that for 
which they were designed. Never overload 
equipment such as hoists, jacks, axle and chassis 
stands or lifting slings. Damage caused by 
overloading is not always immediately apparent 
and may result in fatal failure when the equipment 
is used another time. Do not use damaged tools or 
equipment, mainly high-speed equipment such as 
grinding wheels. The damaged grinding wheel can 
break up without warning and cause serious 
injury. 
Wear suitable eye protection when using the 
grinding or sand blasting equipment. Wear a 
suitable breathing mask when using the abrasive 
blasting equipment, working with asbestos-based 
materials or while using the spraying equipment. 
Make sure there is adequate ventilation to control 
dusts, mists and fumes. Always maintain the tools 
in a neat and good condition for quality repairs. 
Always Keep the tools and equipment calibrated. 
Guidance to safe working 
Always follow the safety instructions provided by 
the respective manufacturers for all the equipment, 
tools, safety gears etc. used in the workshop. 
Precautions for repairing a vehicle in 
the workshop 
When working on the vehicle in the workshop 
always follow the below mentioned procedures: 
Make sure that the area has adequate 
ventilation to disperse exhaust gases such as 
carbon monoxide and other fumes. 
When the engine is running, use adequate 
ventilation or an extraction hose to remove 
exhaust fumes. 
Make sure that the work area such as floors, 
workbenches, tools are clean and free from 
debris and clutter. 
Be sure that all necessary tools and 
measuring equipment are available before 
starting any work. 
Use FUSO Service Tools when they are 
required. 
Do not allow other people near the vehicle 
during servicing. 
Always engage the parking brake and/or use 
wheel chocks to prevent the vehicle from 
moving. 
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3 
Shop Manual - General 
Information 
Ensure there is adequate space around the 
vehicle to lift the vehicle and remove the 
wheels, if necessary. 
Do not let fuel, coolant and other fluids spill 
over electrical and hot vehicle parts. 
 A 
v 
o 
i 
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a 
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e 
dc 
o 
ntact with fluids. 
The battery should be disconnected while, 
working on the engine, underneath the vehicle 
or if the vehicle is raised. 
Cover seats and carpets, wear aprons and 
wash hands or wear gloves before working 
inside the vehicle. 
Avoid spilling hydraulic fluid or battery acid 
on paint work. Wash off with water 
immediately on contact. Use Polythene sheets 
to protect carpets and seats. 
Protect temporarily exposed screw threads by 
fitting plastic caps. 
While using the welding equipment on the 
vehicle, keep a suitable fire extinguisher 
readily available. 
Preparation before Dismantling the 
Vehicle Parts 
Clean components and surrounding area prior 
to removal. 
Blank-off any openings exposed by 
component removal using grease proof paper 
and masking tape. 
Using plastic caps or plugs immediately to 
seal fuel, oil or hydraulic lines when separated 
to prevent loss of fluid and entry of dirt. 
Close the open ends of oil ways, exposed by 
component removal with tapered hardwood 
plugs or readily visible plastic plugs. 
Before dismantling the component, clean it 
thoroughly with a recommended cleaning 
agent. Check whether the agent is suitable for 
all materials of the component. 
After a component is removed, place it in a 
suitable container/tray. Use a separate 
container/tray for each component and its 
associated parts. 
Dismantling of the vehicle parts 
Observe cleanliness while dismantling the 
components, particularly brake, fuel or 
hydraulic system parts. A particle of dirt or 
cloth fragment can cause dangerous 
malfunction if trapped inside the system. 
Blow out all tapped holes, crevices, oil-ways 
and fluid passages with an air line. Ensure 
that any O-rings used for sealing are correctly 
replaced or renewed. 
Use marking ink to identify mating parts and 
ensure correct reassembly. If a centre punch 
or scriber is used they may initiate cracks or 
distortion of components. 
Wire the mating parts to prevent accidental 
interchange (e.g. roller bearing components). 
Label parts which are to be renewed and 
those which require further inspection before 
reassembly. Place these parts in separate 
containers from those containing parts for 
rebuilding. 
Do not discard a part due for renewal until it 
has been compared with the new part, to 
ensure that its correct replacement has been 
obtained. 
Removal of Parts 
While correcting a problem, try to determine its root 
cause. Begin to work only after first learning which 
parts and subassemblies need to be removed and 
disassembled for replacement or repair. After 
removing the part, plug all holes and ports to 
prevent entering of foreign materials. 
Disassembly of Parts 
If the disassembly procedure is complex and 
requires many parts to be disassembled, all parts 
should be temporarily marked in a place that will 
not affect their performance or external appearance 
and identified so that reassembly can be performed 
with ease and efficiency. 
Inspection during Removal/Disassembly 
of Parts 
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efully 
inspected for malfunctioning, deformation, 
damage, and other problems. 
Arrangement of Parts 
All disassembled parts should be carefully arranged 
for reassembly. Be sure to separate or otherwise 
identify the parts to be replaced from those that will 
be reused. 
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4 
Shop Manual - General 
Information 
Cleaning of Parts 
All parts to be reused should be carefully and 
thoroughly cleaned by using the appropriate 
cleaning agent and method. 
Installation of Parts 
Standard values, such as torques and certain 
adjustments, must be strictly adhered to while 
reassembling the parts. 
Parts such as oil seals, O-rings, Cotter Pins, 
Lock Washers, Nylon nuts etc should be 
replaced with new ones if removed. 
Specified oil/lubricant should be applied to 
the moving components or parts. 
Specified oil or grease should be applied at 
the prescribed locations such as oil seals 
before reassembly. 
Adjustment of Parts 
Use recommended/appropriate gauges and testers 
while making adjustments. 
General Inspection 
Never inspect a component for wear or 
dimensional check unless it is absolutely 
clean. Slight smear of grease can conceal an 
incipient failure. 
When a component is to be checked 
dimensionally against figures quoted for it, 
use correct equipment (surface plates, 
micrometers, dial gauges, etc.) in serviceable 
condition. Makeshift checking equipment is 
dangerous. 
Reject a component if its dimensions are 
outside the quoted limits, or if damage is 
apparent. A part may however be refitted if its 
critical dimensions are given to the prescribed 
size limits, and is otherwise satisfactory. 
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5 Maintenance Section 
Shop Manual - Product 
Information 
1 
Product Information 
Vehicle Identification 
Vehicle Identification Number 
The VIN - Vehicle Identification Number is fixed in 
all vehicles. The VIN is unique for every vehicle. 
VIN plate is fitted on the closing pillar of the 
codriver door. 
The VIN is also punched on the left side of the 
frame which can be viewed from the gap between 
the front left side tyre and mudguard. 
How to Read Vehicle Identification 
Number (VIN) 
DICV-GEN-2785 
xxx xxxxxxxxx 
xxxxxxxxx 
Permissable total weight 
Permissible combination weight 
Permissible axle load axle 1 
Permissible axle load axle 2 
Permissible axle load axle 3 
Permissible axle load axle 4 
Kg 
Kg 
Kg 
Kg 
Kg 
Kg 
1- 
2- 
3- 
4- 
TYP 
VIN MEC 
DAIMLER INDIA COMMERCIAL VEHICLES PVT LTD 
DICV-GEN-3770 
WMI (World Manufacturer Identifier) code 
Model 
052: FIV1PFX2L 4×2 Wheelbase 3760mm 
054: FIV1PHX2L 4×2 Wheelbase 4250mm 
Engine type & power 
4: 4D37, 125 kW 
Type of drive 
A: Right-hand drive 
P: Left-hand drive 
XXXX 
XXXX 
XXXX 
X 
DICV-GEN-3771 
1 
2 
34567 
MEC 
P XXXXXX 
1 
2 
3 
4 
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5 Maintenance Section 
Shop Manual - Product 
Information 
2 
Aggregate Identification 
Engine 
The engine serial number plate is fitted on left 
hand side of the engine on the crankcase. 
The engine serial number is also punched on the 
right side of the engine on the crankcase. 
Vehicle model coding system 
Month of manufacturing/ Year of manufacturing 
Plant code 
Vehicle serial number 
DICV-GEN-3768 
FZ24802 
Basic vehicle type F Cab over truck 
Gross vehicle 
weight 
I 12 tons 
Cab variant 
V Width 1995mm 
Length 1620mm 
Chassis structure 1 4x 2, Rigid 
Engine Model 
P 4D37 
Wheel base 
F 3760mm 
H 4250mm 
Gross vehicle 
weight 
X1 
2 
t 
o 
n 
s 
Engine class 
2 125kW 
Steering 
L LHD 
RR 
H 
D 
DICV-GEN-3769 
1 
7 
4 
35 
2 
8 
6 
FIV1PFX2 
9 
L 
1 
2 
3 
4 
5 
6 
7 
8 
9 
5 
6 
7 
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