Mahindra Genio DC BS-IV Скачать руководство пользователя страница 1 | Manualshive

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©

2011

Mahindra

&

Mahindra

Ltd

.

All

rights

reserved.

This

book

may

not

be

reproduced

or

copied,

in

whole

or

in

part,

without

the

written

permission

of

Mahindra

&

Mahindra

Ltd.

MAINTENANCE

MANUAL

(BS-III/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
MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M&M AUTHORIZED
DEALER SERVICE CENTERS

.

RELEASED BY –

TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.

Rev1 – JU

LY

2011

MAN-00135

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2
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Содержание Genio DC BS-IV

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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