Maintenance Manual
MAN-00
135
GENIO DC
(BS-III & BS-IV)
JULY 2011
/Rev1
The repair methods given by the manufacturer in this document are based on the technical specifications
,
current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of
or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution
© 2011 Mahindra & Mahindra Ltd.
27
705-MAT-0019 : 0.70 hrs.
BRAKE/ CLUTCH FLUID – REPLACE
Clutch /Brake Fluid – DOT4 standard /SAE J1703/IS 8654
Capacity: 0.9 Lit.
Description –
The brake fluid should be replaced once a year or every 40,000 Kms – whichever is earlier. Inspect
first at 5000kms then at every 10000kms from 20000kms onwards. The fluid and reservoir are
common for Brake and Clutch system in
GENIO
. Fluid reservoir is mounted on the brake master
cylinder.
Refer above illustration.
There are three compartments in reservoir; fluid is being
supplied to front brake circuit, Clutch master cylinder and rear brake circuit.
Fluid replacement procedure –
Open the bleed screws on Callipers, Rear brake drums, LSPV and Slave cylinder and allow the fluid
to drain out completely. To ensure complete draining, brake and clutch pedal can be depressed.
After the fluid is drained, hand tightens bleed screws on Front Callipers, Rear brake drums, LSPV
and Slave cylinder. Refill recommended fluid in the reservoir till the MAX mark. Ensure that fluid is
getting in and air in the system getting passed through bleed screws; tighten bleed screws as soon
as continue flow of fluid starts. Both systems bleeding need to be done.
Refer below mentioned brake bleeding sequence and illustration -
1. Rear left
2. Rear right
3. LSPV
4. Front left
5. Front right
The procedure at each of the bleed point is to pump the pedal for 2 to 3 times, open the bleed
screw by 1/4th turn, close the bleed screw. Again pump the pedal for 2 to 3 times then open the
bleed screw keeping the pedal pressed down. Close the bleed screw and release the pedal. Repeat
the operation until no bubbles are coming. The Bypass valve is inbuilt in the LSPV & it should be
bleed at the time of bleeding.
Common Fluid Reservoir for Brake & Clutch System
Hose connected
from Reservoir
to CMC
