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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. 

28 

NOTE:

 It is also advisable to keep the engine running at idling so that the pedal travel is complete. 

 
 

 
 
 
Refill the fluid in clutch system; ensure that the fluid is getting refilled in system as well as air in 
the system is getting pass through the bleed screw on slave cylinder. Tightens  bleed screws as 
soon as continue flow of fluid starts. Bleed the Clutch  System  and ensure no air trapped in the 
system.  
 

 

While bleeding we suggest that the bleed screw nipple is fitted with a 
transparent plastic pipe. This pipe should be submerged in a glass bottle filled 
with brake fluid.  

 

If any air bubbles are present then it can be easily seen in the container as well 
as the plastic pipe. 

 

The reservoir should be continuously filled with brake oil to avoid air entering 
thru the empty reservoir. 

 

Always use brake fluid from a new sealed container to do this activity (an open 
container may have got contaminated with moisture.) 

 

Recommended replacement interval is at every 40,000 kms. or 1 year, 
whichever is earlier.  

 

 

 

Summary of Contents for Genio DC BS-IV

Page 1: ...I BS IV www teknetmahindra com ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP TO DATE AT THE TIME OF PUBLICATION HOWEVER SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE THIS MA...

Page 2: ...hese operations are Adjust A Inspect Correct I Replace R Clean C The maintenance periods are specified in Kilometers Kms Standard Operating Procedures SOP Each maintenance operation is coded by a oper...

Page 3: ...pport the specified location with a safety stand When lifting up the vehicle use appropriate safety equipment Parts and tools Before starting operation prepare tool stand MST Gauges oils and parts for...

Page 4: ...its 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 M...

Page 5: ...05 MAT 0010 13 Fuel filter element Replace 705 MAT 0011 14 Fuel tank Clean 705 MAT 0012 15 Water sediments drain Fuel filter 705 MAT 0013 16 Transmission oil Replace 705 MAT 0014 17 Differential oil R...

Page 6: ...ty 6 0 Lit Park the vehicle on level ground 2 post lift 4 post lift If the activity is done on a 2 post lift ensure that the LSPV spring is disconnected before lifting the vehicle After lowering re co...

Page 7: ...LEVEL LEAK CHECK Ensure that the vehicle is parked on level ground 2 post lift 4 post lift If the activity is done on a 2 post lift ensure that the LSPV spring is disconnected before lifting the vehic...

Page 8: ...penalty prosecution 2011 Mahindra Mahindra Ltd 5 705 MAT 0003 0 20 hrs ENGINE OIL FILTER REPLACE Never use a wrench spanner to tighten the oil filter Oil filters need to be replaced during engine Oil...

Page 9: ...tion 2011 Mahindra Mahindra Ltd 6 705 MAT 0004 0 05 hrs AUTO TENSIONER CHECK Auto tensioner to be check at 60000 80000kms and it is recommended to replace it at every 100000kms Auto Tensioner Inspecti...

Page 10: ...d shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 7 705 MAT 0005 0 60 hrs AUTO TENSIONER REPLACE Auto tensioner to be check at 60000 80000kms and it is recommended to replace it at...

Page 11: ...DRIVE BELT CHECK Belt Type 6PK 1610mm GATES make Belt Tension Value 114 5 Hz ACCESSORY DRIVE BELT TO BE CHECK FOR Refer illustrations below 1 Abrasion 2 Cracking 3 Improper Install 4 Uneven Rib Wear 5...

Page 12: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 9 Recommended belt tension is 114 5 Hz To be check between Altern...

Page 13: ...Hz Recommended belt tension is 114 5 Hz To be check between Alternator A c Compressor Accessory Drive Belt tension to be check at 60000kms 80000kms Accessory Drive belt replacement interval is every...

Page 14: ...nalty prosecution 2011 Mahindra Mahindra Ltd 11 705 MAT 0008 0 05 hrs COOLANT LEVEL CHECK Never remove the radiator cap when the engine is hot Never mix MAXIMILE coolant with water Maximile coolant is...

Page 15: ...p when the engine is hot Never mix MAXIMILE coolant with water Maximile coolant is premixed ready to use Recommended to change the coolant at 60000 then every 80000kms Use Maximile ULTRA COOL Don t us...

Page 16: ...TER REPLACE Never try to clean and reuse the Air filter cartridge It is recommended to replace the air filter cartridge at every 60000kms and in case vehicle runs in very dusty condition replace air f...

Page 17: ...unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 14 705 MAT 0011 0 30 hrs FUEL FILTER REPLACE Always use genuine fuel filter assembly Fuel filter to be replaced...

Page 18: ...d before lifting the vehicle After lowering re connect the LSPV spring and ensure that the setting height is correct There is no drain plug provided on Fuel tank Take safety precaution while taking fi...

Page 19: ...nnel 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 16 705 MAT 0013 0 10 hrs WATER SED...

Page 20: ...t If the activity is done on a 2 post lift ensure that the LSPV spring is disconnected before lifting the vehicle After lowering re connect the LSPV spring and ensure that the setting height is correc...

Page 21: ...Ltd 18 705 MAT 0015 0 20 hrs DIFFERENTIAL OIL REPLACE Differential Oil MAXIMILE DO EXL SAE 80W90 Capacity 1 8 Lit If the activity is done on a 2 post lift ensure that the LSPV spring is disconnected...

Page 22: ...hibited 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 wil...

Page 23: ...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 prosecuti...

Page 24: ...Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 21 Remove bundy tube connected on wheel cylin...

Page 25: ...ck washer Remove plane washer from axle Back plate bearing carrier bearing and axle can be separated Avoid damages and ensure that shaft seal is intact Cleaning Inspection Clean Inspect the Bearing ca...

Page 26: ...is to be fitted on LH side axle shaft Left Hand Rough Thread LH marking Right Hand Rough Thread No any mark Match the washer lug to the lock nut groves At least one lug to be locked Use small drift f...

Page 27: ...d 24 705 MAT 0221 0 10 hrs PROPELLER SHAFT SLIDING JOINT LUBRICATE Grease Grade MAXIMILE LCG NLGI 2 3 Park the vehicle on level ground 2 post lift 4 post lift Always use recommended grease only Propel...

Page 28: ...0017 0 15 hrs LSPV SETTING LSPV setting should be carried out with the vehicle on the ground or on a 4 post lift The vehicle should not be lifted using a 2 post lift while doing this operation The Spe...

Page 29: ...ation Capacity 0 9 Lit GENIO is fitted with common Fluid reservoir for Brake and Clutch System There are three different compartments 2 compartments for brake front and rear circuits and another for c...

Page 30: ...e 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 replacemen...

Page 31: ...NOTE It is also advisable to keep the engine running at idling so that the pedal travel is complete Refill the fluid in clutch system ensure that the fluid is getting refilled in system as well as ai...

Page 32: ...nboard outboard then replace both the pads If pads on one wheel only are worn even then replace the other wheels also Any excessive difference between inboard and outboard wear indicates either bent o...

Page 33: ...onnected before lifting the vehicle After lowering re connect the LSPV spring and ensure that the setting height is correct Whenever the shoe linings are replaced replace both RH LH assemblies as a se...

Page 34: ...pe and apply Parking Brake to check the effectiveness Release the Parking Brake check the free rolling Loosen or tighten the adjuster nut to achieve the correct setting 2 Check the parking cables espe...

Page 35: ...Use calibrated torque wrenches Do not over torque than recommended values Inspect Front suspension first at 5000kms 10000kms 20000kms and then every 20000kms Inspect Rear suspension bolt torque check...

Page 36: ...voided bush in case it is removed Inspection of front suspension bush is recommended at every 40000kms Upper arm is fitted with voided bush on both sides Lower arm is fitted with voided bush at its r...

Page 37: ...d 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 34 Correct fitment identifi...

Page 38: ...Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 35 705 MAT 0026 0 20 hrs REAR SUSPENSION BUSHES SHACKLE PIVOT INSPECT Rear Suspensi...

Page 39: ...son 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 36...

Page 40: ...5mm GATES make POWER STEERING BELT CHECK Refer illustrations Check the belt visually for 1 Abrasion 2 Cracking 3 Improper Install 4 Uneven Rib Wear 5 Misalignment 6 Chunk out 7 Gravel penetration 8 Pi...

Page 41: ...Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 38 Recommended belt tension for Power Steering Pump driv...

Page 42: ...belt noise If tightened excessively then it can cause the power steering pump failure Power Steering Pump Drive Belt tension to be check at 5000 20000 and then at every 20000kms and adjust if required...

Page 43: ...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 personn...

Page 44: ...a Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 41 Pre Work for Wheel Alignment Process Tyre pressure Ensure correct tyre pressure...

Page 45: ...to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 42 Ride height Is the verticle distance between front camber bolt nut side end center to the ground plane The...

Page 46: ...l be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 43 705 MAT 0031 0 10 hrs BATTERY ELECTROLYTE LEVEL CHECK Battery Electrolyte Level Check to be inspected at 5000kms 10000kms 15000kms 200...

Page 47: ...e 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...

Page 48: ...Auto Start Stop Where fitted 8 Low oil pressure indicator 9 Parking brake indicator 10 Brake system warning indicator 11 Water in fuel indicator 12 OBD MIL Check lights wiper washer horn hazard switc...

Page 49: ...rs Washers to be inspected at 5000kms 10000kms and then every 10000kms Lighting Control Turn Indication When the lever is pushed down to position C it causes the turn signals on the right side of the...

Page 50: ...34 0 30 hrs HEADLAMP AIMING ALIGNMENT Headlamp alignment in GENIO can be done by methods called IN THE DARK ROOM Ensure that the a Check and ensure all four tyre pressures are as per specification b H...

Page 51: ...Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 48 Refer above illustration 1 Keep the vehicle at a distance of 10 meter from the black scre...

Page 52: ...20 hrs HVAC FILTER CLEAN Clean mesh every service interval Check the entire system for leaks and recharge if required HVAC FILTER CLEAN Refer above illustrations 1 Open and remove the Glove Box Refer...

Page 53: ...d will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 50 705 MAT 0036 0 25 hrs DOOR SETTING Door setting to be done at first 5000kms service schedule...

Page 54: ...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 Mahin...

Page 55: ...unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 52 705 MAT 0038 0 40 hrs BODY MOUNTING BOLTS TIGHTEN Park the vehicle in inspection pit 2 post lift 4 post lift...

Page 56: ...e Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 53 705 MAT 0039 0 10 hrs EXHAUST SYSTEM CHECK Park the vehicle...

Page 57: ...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 pr...

Page 58: ...of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 55 MAINTENANCE CHECK SHEET 5 000 KMS 3 Months Maintenance Item Action to...

Page 59: ...he 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 56 MAINTENANCE CHE...

Page 60: ...zed use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd 57 MAINTENANCE CHECK SHEET 20 000 KMS 12 Months Maintenance Item Action to be taken Remark Engine oil R Engine oil filter...

Page 61: ...han 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 58 MAINTENANC...

Page 62: ...liable for penalty prosecution 2011 Mahindra Mahindra Ltd 59 MAINTENANCE CHECK SHEET 40 000 KMS Maintenance Item Action to be taken Remark Engine oil R Engine oil filter Maximile Universe R Coolant I...

Page 63: ...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 60 MAINTENANCE CHECK SHEET 50...

Page 64: ...e for penalty prosecution 2011 Mahindra Mahindra Ltd 61 MAINTENANCE CHECK SHEET 60 000 KMS Maintenance Item Action to be taken Remark Engine oil R Engine oil filter Maximile Universe R Auto tensioner...

Page 65: ...han 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 62 MAINTENANC...

Page 66: ...n 2011 Mahindra Mahindra Ltd 63 MAINTENANCE CHECK SHEET 80 000 KMS Maintenance Item Action to be taken Remark Engine oil R Engine oil filter Maximile Universe R Auto tensioner I Accessory drive belts...

Page 67: ...he 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 64 MAINTENANCE CHE...

Page 68: ...for penalty prosecution 2011 Mahindra Mahindra Ltd 65 MAINTENANCE CHECK SHEET 1 00 000 KMS Maintenance Item Action to be taken Remark Engine oil R Engine oil filter Maximile Universe R Auto tensioner...

Page 69: ...an 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 66 MAINTENANCE...

Page 70: ...penalty prosecution 2011 Mahindra Mahindra Ltd 67 MAINTENANCE CHECK SHEET 1 20 000 KMS Maintenance Item Action to be taken Remark Engine oil R Engine oil filter Maximile Universe R Coolant I Air filt...

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