Mahindra ROXOR HDUV 2023 Operator'S Manual Download Page 81

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22-5

Item

Maintenance Interval (Use interval that occurs first

for each item)

Maintenance Procedure

Hours of Operation

Calendar

Miles (Km)

A =

It is recommended that the maintenance procedure be performed by an

Authorized Mahindra Dealer/Service

facility.

S =

For a ROXOR subjected to

Severe use,

perform the maintenance procedure more frequently than the recommended intervals.

Engine Mounts

–

60 M

–

• Inspect for wear or damage. Replace as

needed

Valve Timing /

Clearance

–

• n/a - self - adjusting hydraulic lash

A/S

Auxiliary / Parking

Brake

As needed

• Lubricate and adjust as needed

–

Headlight Aim

As needed

• Adjust as needed

Wheel Alignment;

Toe Adjustment

As needed

• Adjust as needed. Align whenever parts are

replaced during routine maintenance

Maintenance

Summary of Contents for ROXOR HDUV 2023

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Page 3: ...ad vehicle can expose you to chemicals including engine exhaust carbon monoxide phthalates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing ...

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Page 5: ... s Responsibilities 6 2 Passenger Responsibilities 6 2 Occupant Restraint System 6 3 Riding Carefully 6 3 Terrain Condition 6 3 Stopping the Engine and Parking 6 4 7 Important On Product Labels 7 1 ANSI Labels 7 1 EPA Labels 7 4 Manufacturer Labels 7 5 8 Riding Gear 8 1 Helmets and Eye Protection 8 1 Additional Riding Gear 8 2 9 Prepare to Ride 9 1 Pre Ride Inspection Checklist 9 1 Post Ride Inspe...

Page 6: ...ower Outlet 12 3 Storage Compartments 12 3 Cup Bottle Holders 12 3 Rear Cargo Area 12 3 Tailgate 12 3 Fuel Reservoir Cap 12 4 13 Electrical Distribution 13 1 14 Fuel Diesel 14 1 Fuel Requirements 14 1 Fueling Procedure 14 1 15 Break in Period 15 1 Operation During Break In 15 1 Tips for Maximizing Durability 15 1 16 Avoiding Accidents 16 1 17 OFF Road Operation 17 1 18 General Driving Techniques 1...

Page 7: ...ng and Pulling Loads 19 2 20 Transporting 20 1 Trailering 20 1 Towing 20 2 21 Lifting and Supporting 21 1 22 Maintenance 22 1 Severe Dusty Conditions 22 1 Scheduled Maintenance Chart 22 2 23 Maintenance Procedures 23 1 Maintenance Tips and Precautions 23 1 Clean Spark Arrester 23 1 Clean and Inspect Brakes 23 2 Check Brake Fluid Level and Leak Check 23 3 Check Differential Oil Levels and Leak Chec...

Page 8: ...al and Rust Prevention 24 1 Storage and Preseason Preparation 24 1 25 Technical Information 25 1 Product Identification Number 25 1 Engine Identification Number 25 1 Noise Emission Control System 25 1 Acts Presumed to Constitute Tampering 25 2 26 Specifications 26 1 Fluid Specifications and Quantities 26 1 Vehicle Specifications 26 2 27 Troubleshooting 27 1 28 Limited and EPA Warranties U S and Ca...

Page 9: ...er or visit our website WWW ROXOROFFROAD COM 1 1 Improvements MAgNA s policy is one of continuous improvement and the right to change prices specifications or equipment at any time without notice is reserved All data given in this book is subject to production variations Dimensions and weight are approximate only and illustrations do not necessarily show vehicles in standard conditions For exact i...

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Page 11: ...lly comprehend and abide by the content of this Operator s Guide before you operate the Mahindra ROXOR Offroad Side x Side Also read and become familiar with all safety labels on your ROXOR Failure to follow all on product safety label warnings and the warnings contained in this Operator s Guide may result in severe injury or death of the operator passengers and bystanders Getting Started ...

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Page 13: ...ent of its products without imposing upon itself any obligation to install them on products previously manufactured We reserve the right to change modify or cancel specifications designs features and colors without notice or obligation Some differences between the manufactured product and the descriptions and or specifications may exist Keep this Operator s Guide with the vehicle so you and any ot...

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Page 15: ...blic if not avoided potential for a non immediate hazard presenting a lesser threat of injury resulting in minor or moderate injuries to occupants and or general public if not avoided potential for a non immediate hazard presenting a risk to property and or equipment damage The entire contents of this Operator s Guide should be treated as safety instructions They should be scrupulously adhered to ...

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Page 17: ...idely regarded as safe to handle and store in its liquid form However diesel fuel in its vapor form can be dangerous especially at temperatures above 100 F 38 C The vaporization rate of diesel fuel increases as the temperature increases In the presence of a vapor accelerant such as fan forced air or oxygen the diesel fuel can begin to vaporize even faster Help reduce the risk of diesel fuel hazard...

Page 18: ...ngly MAgNA parts and accessories have been specifically designed for use on the Mahindra ROXOR Offroad Side x Side We strongly recommend that all parts and accessories you add to your ROXOR be genuine Mahindra parts and accessories so as not to affect your safety EPA compliance or factory limited warranty MAgNA warrants that the Accessories as further defined below are free from defects in materia...

Page 19: ...ssions safety and handling resulting in injury or death Any changes to factory installed wheel and tire size will adversely affect the operation of this unit s Dash Cluster and Engine Control Unit ECU Altering the Dash Cluster and or ECU may cause driveability issues and potentially void the unit s warranty Consult an authorized ROXOR Dealer for more information Safety Information General Precauti...

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Page 21: ...ver allow anyone to operate your ROXOR unless they are responsible and can be trusted with an off road vehicle like the ROXOR Consider supervising new operators and setting rules and limits for anyone using your ROXOR e g whether they can carry a passenger s what they may do with the vehicle where they may ride etc Always discuss the safety information with anyone who will be using the ROXOR Be su...

Page 22: ...ugs or alcohol or if tired or ill These effectively slow your reaction time and impair judgment Operators must be at least 16 years of age or older with a valid driver s license Children under the age of 16 may not have the physical or psychological capability to operate the ROXOR without risk of injury or death 6 3 Passenger Responsibilities All passengers must be properly seated in their seats a...

Page 23: ...d spots When it is safe to proceed in reverse go slowly Never exceed the stated load limits for this vehicle Cargo must be properly secured Reduce speed allow for greater braking distance and follow all instructions in section 19 Moving Loads and Doing Work Always remember that the ROXOR is heavy Its pure weight alone may entrap you should it tip or rollover 6 6 Terrain Condition The ROXOR is not ...

Page 24: ...ing the Engine and Parking Release accelerator pedal and use brakes to completely stop the ROXOR Turn the ignition switch to the OFF position and remove key from ignition switch When stopped or parked always put gear shift lever in first gear and set parking brake by pushing the button in pulling straight up and then releasing button To release parking brake pull up slightly push and hold button i...

Page 25: ... years or both 7 1 ANSI Labels The labels in this section are to comply with the requirements set forth by the American National Standards Institute ANSI specifically standard ANSI Z535 4 2007 The ROXOR is delivered with several labels containing important safety information Some of these labels are affixed to the ROXOR for the safety of the operator passengers and bystanders They need to be clean...

Page 28: ...hat have EPA labels on them make sure to order the applicable safety warning labels if not already installed on the replacement part The ROXOR is delivered with several labels containing important safety and emissions information They need to be clean and visible at all times If missing or damaged they need to be replaced Replacement labels are free of charge and can be requested from a ROXOR auth...

Page 29: ...ions The ROXOR is delivered with several labels containing important safety information Some of these labels are affixed to the vehicle for the safety of the operator passengers and bystanders They need to be clean and visible at all times If missing or damaged they need to be replaced Safety labels are free of charge and can be requested from MAgNA with a registered Product Identification Number ...

Page 31: ...ments If you choose an open face helmet a snap on safety shield is preferred An open face helmet does not offer the same protection for the face and chin The ROXOR s Roll Over Protection Structure ROPS and side nets cannot prevent all objects from entering the cockpit area In rough terrain conditions your head may make contact with the ROPS or objects outside the ROXOR The best helmet is no guaran...

Page 32: ...e boot with non slip soles are preferred and will help you keep your feet firmly on the floor and foot controls Long shoelaces should be avoided they can get tangled in the foot controls and prevent you from exiting the ROXOR For cold weather riding avoid oversized boots that may get trapped in the foot controls and prevent the proper operation of the ROXOR Clothing Long sleeve shirts and long pan...

Page 33: ...tion Checklist What to do before starting the engine Check tire pressure and condition Recommended cold tire pressure is 28 psi Check wheels for damage and abnormal play Make sure lug nuts are torqued to between 71 105 Nm Check cleanliness of radiator cooling fins Check engine oil level Maintain between the two notches on dip stick Check engine coolant level Maintain between HIGH and LOW lines on ...

Page 34: ...erates freely and it returns to the rest position when released Press on the brake pedal and make sure you feel firm resistance and it returns to the rest position when released Check the fuel level Adjust mirrors to your preferences If equipped What to do after starting the Engine Check if steering wheel operates freely by completely turning it from side to side Turn the ignition switch to OFF to...

Page 35: ...s top off as necessary Inspect and remove all dirt and debris from your engine transmission exhaust and other components that can get hot during a ride Check for fluid leaks in the engine compartment and under the ROXOR Properly park the ROXOR on the flattest surface available Put gear shift lever in first gear and set parking brake by pushing the button in pulling straight up and then releasing b...

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Page 37: ... vehicle with a manual transmission learning on the ROXOR while driving off road is not advisable A manual transmission requires the operator to shift gears themselves with proper timing and coordination This activity must become second nature in a controlled environment before operating on difficult terrain The clutch pedal is located at the far left and is required to shift gears Always fully de...

Page 38: ...ould also familiarize yourself with the distance required to see obstacles behind you Place an orange cone or other non destructible item close to the rear bumper and then pull forward until you can see the item from the driver s seat You can even practice backing up to these items without hitting them Take note of the distances Emergency Engine Stop While driving at a slow speed turn off the igni...

Page 39: ...heir function 11 2 Keys The ROXOR is delivered with keys for ignition storage compartment and as equipped door keys Neither of these two lockable storage compartments is waterproof All electronics or other valuables stored in these compartments should be adequately protected by other means 11 3 Ignition Switch The ignition switch is located on the dash panel to the right of the steering wheel OFF ...

Page 40: ...d from the start position If this statement is not true contact and return your ROXOR to an authorized dealer START position in this position the starter is engaged You should only hold the ignition key in this position until the engine starts then release the ignition key Do not hold the ignition key in the START position for more than 10 seconds at a time as this can overheat the starter and dam...

Page 41: ... that indicates vehicle speed in miles per hour or kilometers per hour Odometer digital readout below the speed that records the total distance traveled in miles or kilometers Trip Odometer using the same digits as the Odometer there are two available trip odometers A B switchable using the Mode Button Hours Meter the total hours on your vehicle will display below the fuel level indicator only whe...

Page 42: ... the vehicle is driven Low Fuel Indicator yellow light on steady when fuel level is at two gallons or less Light flashes when fuel level sensor has failed to provide a signal Check Engine Indicator yellow light on steady or flashing when an emissions related trouble code has been set return vehicle to an authorized Mahindra dealer for service Water In Fuel Indicator yellow light on steady when wat...

Page 43: ...is below the minimum level or the parking brake is set Wait To Start Indicator when the key is in IGN ON position the yellow light is on steady for up to 100 seconds in extreme cold temperatures Engine intake air heater is on due to engine temperature wait for light to go out before cranking High Beam Head lamp Indicator blue light on steady when headlamp switch is in the high beam position Fuel G...

Page 44: ...ould be pulled out If Air Conditioning is desired the middle knob should be pushed in and the right dial can be adjusted for desired temperature clockwise for cooler temperature There are six forward facing air registers and two bottom facing registers located at the bottom of the dash panel on the passenger side In addition there are two defrost registers at the top of the dash panel one at the c...

Page 45: ...ring wheel 11 8 Accelerator Pedal Of the three pedals located on the driver s side floor area the accelerator pedal is on the far right The accelerator pedal controls the engine speed and should be operated smoothly and reasonably The accelerator pedal is spring loaded and should return to its rest position idle when not pressed Take your ROXOR to an authorized dealer if you are experiencing probl...

Page 46: ... always depress the clutch fully and let up on the accelerator pedal before moving the gear shift lever to the next gear Bring the ROXOR to a complete stop with engine running before shifting into reverse to prevent gear damage and ease engagement 11 12 Transfer Case Lever The transfer case shift pattern is located on top of the transfer case lever knob Use the transfer case lever to switch betwee...

Page 47: ...at The driver s seat can be adjusted forward and backward To adjust seat move the seat lever up to unlock the seat Release the lever to lock the seat into desired position To help prevent a loss of control never adjust the seat position while driving A loss of control while driving could result in severe injury or death 12 3 Passenger Seat The passenger s seat can be adjusted forward and backward ...

Page 48: ...a rollover or any other accident 12 6 Side Nets Doors The ROXOR is equipped with operator and passenger side nets or doors They are designed to help arms and legs remain inside the cockpit Side nets or doors can also help keep brush and debris out of the cockpit The side nets or doors are an integral part of the safety system and must not be removed Removal of these severely increases the risk of ...

Page 49: ...ea may be used for hauling various types of cargo Properly secure all loads in the rear cargo area using the factory supplied cargo tie downs only To help reduce the risk of loss of control or loss of load use the cargo area in accordance with section 19 Moving Loads and Doing Work Never carry any passengers in the rear cargo area Passengers in this area cannot be properly restrained and could be ...

Page 50: ...All Rights Reserved 12 13 Fuel Reservoir Cap The fuel reservoir cap is located on the right side behind the rear wheel Refer to 14 1 Fuel Requirements or 14 2 Fueling Procedure for more on fuel related information Equipment ...

Page 51: ...1 13 Electrical Distribution Power Distribution Center This component is located in the engine bay on the driver side The Power Distribution Center cover contains a similar graphic to the one shown here for convenience Electrical Distribution ...

Page 52: ...A F15 Empty F16 Exterior Lighting 20A F17 Instrument Gauge 2A F18 Diagnostic Port 5A F19 Alternator Field Excitation 5A Power Distribution Center Fuse No Circuit Fuse Rating F20 LED Lightbar Accessory 20A F21 High Beam Headlight 20A F22 ECU Switched Power 5A F23 ECU Power 2 10A F24 Brake Light Seat Belt Indicator 10A F25 Engine Accessory 15A F26 ECU Power1 10A F27 Reverse Light 5A F28 Low Beam Hea...

Page 53: ... No Circuit R1 Empty R2 Intake Heater R3 R4 Empty R5 Starter Solenoid R6 ECU Main R7 R8 Empty R9 High Beam Headlight R10 Empty R11 Alternator Field Excitation R12 Power Outlet R13 LED Lightbar Accessory R14 Exterior Lighting Electrical Distribution ...

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Page 55: ...ich would also void all of your warranty coverage 14 2 Fueling Procedure 1 Stop the engine 2 Only fill the fuel tank in a well ventilated area 3 Have the operator and all passengers get out of the ROXOR 4 Unscrew fuel reservoir cap slowly by turning it counterclockwise to remove it 5 Insert the fuel spout into the fuel filler neck 6 Pour fuel slowly so that air can escape from the tank and prevent...

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Page 57: ...ransfer case between 2WD and 4WD High range at low speeds 1 5 mph This also contributes to a good break in and will familiarize you with the effort required to perform this operation while moving Bring the ROXOR to a complete stop with engine running before shifting the transfer case into 4WD Low Range to prevent gear damage and ease engagement The ROXOR can be shifted between 2WD and 4WD High ran...

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Page 59: ...n possible instead drive straight up and down inclines rather than across them If driving across a slope is unavoidable use extreme caution If you feel the ROXOR start to roll over steer downhill if possible Avoid speeding The ROXOR can reach high speeds particularly in challenging off road conditions At higher speeds there is an increased risk of losing control an increased risk of collision and ...

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Page 61: ...e safest path and keeping a close eye on the terrain ahead of them This Mahindra ROXOR Offroad Side x Side should never be operated by someone who is not very familiar with how to control it Persons taking part in this activity have sometimes been met with criticism for the environmental damage incurred by their vehicles Please be courteous and limit your use of the ROXOR to private property or ar...

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Page 63: ...it to a ROXOR authorized dealer 18 2 Driving in Reverse Choosing a safe place to turn around is always preferred whenever possible Be aware that abrupt steering inputs while driving in reverse can increase the risk of a roll over When operating in reverse check that the path behind the ROXOR is free of people and or obstacles When safe proceed with care and caution go slowly and avoid sharp turns ...

Page 64: ... prevent tire spin 18 4 Driving in or on Sand Sand and sand dune riding is a unique experience On sand dunes it is advisable to equip the ROXOR with an antenna type safety flag When riding on sand dunes proceed cautiously if you see another safety flag and remember vehicles can approach you from any direction Slow down and avoid abrupt steering inputs to prevent sliding and roll overs especially o...

Page 65: ... discs which may affect the response time of the braking system periodically apply the brakes 18 6 Driving on Hills and Slopes Avoid parking on slopes if unavoidable put the shift lever in gear set the parking brake and block the tires Approach the tops of hills with caution to avoid a collision with vehicles coming from the other direction It may be necessary to check the terrain conditions on th...

Page 66: ...lect a different route If the front or rear wheels are driven off this type of terrain it will most likely stop moving or roll over Attempting to negotiate drop offs as described above may lead to severe injury or death 18 9 Crossing Obstacles It is best to avoid obstacles whenever possible Operator Passengers should grip steering wheel handhold firmly and keep feet on the floor during all crossin...

Page 67: ...d and changed as needed It is your responsibility to check your local laws related to water crossings Some rivers and streams are protected from activities like this 18 11 Crossing Public Streets Roads or Highways Obey all sign and traffic signals Do not proceed if complete visibility in both directions is hindered Choose an exit point on other side of road then wait for oncoming traffic to pass D...

Page 68: ...here you are planning to go and when they should expect you back Always consider bringing additional clothes tools emergency equipment and a first aid kit and checking the local weather report Find out where you can get additional fuel When group riding be aware that others in your group may not have safety equipment like turn signals Always keep a safe distance between vehicles 18 14 Environment ...

Page 69: ...hicle Load Capacity 1525 lbs 692 kg Maximum Towing Capacity 3 500 lbs 1 588 kg Maximum Tongue Weight 350 lbs 159 kg 19 3 Loading the Rear Cargo Area When loading cargo into the ROXOR position the cargo toward the front and center of the cargo area and as low as possible Verify the tailgate is latched before operating High heavy loads can change the center of gravity of the ROXOR increasing the pot...

Page 70: ...the trailer hitch if installed or winch if installed to pull a load Never try to pull the ROXOR by wrapping chains or straps around its axles cargo tie downs or ROPS Know the Working Load Limit WLL of the strap chain or cable you are using Never stand in the recoil or snap back area this is the area that the strap chain or cable could reach when snapping back if a failure break occurs When using s...

Page 71: ...y and limitations of the ROXOR The trailer and or hitch could fail under the excess load and break away from the ROXOR resulting in personal injury or death Driving off road while pulling a trailer substantially increases the risk of a roll over especially on uneven terrain and slopes Be aware that if the trailer is involved in a rollover it may force the ROXOR to follow resulting in personal inju...

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Page 73: ...ons refer to section 26 2 Vehicle Specifications Straps around axles Straps to trailer tie downs Use extreme caution when securing the axles do not wrap straps or chains completely around the axles so as not to damage the brake lines resulting in severe injury or death Make sure no loose objects are present inside the ROXOR or in the rear cargo area during transportation as they can be lost or wor...

Page 74: ...brake actuation systems Towing Preparation Procedure 1 Verify tires are inflated to 28 psi 2 Verify vehicle alignment meets manufacturers specification 3 Verify both differentials the transfer case and transmission fluid levels are at their recommended levels 4 Verify all grease locations are properly lubricated 5 Do not secure the steering wheel it must be free to rotate for vehicle to track corr...

Page 75: ...ed under the right and left frame rails If lifting just the front or just the back be sure to block the opposite wheels using rocks logs or wheel chocks For hoist lifting only use the two front locations and the two rear locations shown here Front Lifting Location Rear Lifting Location Verify the unit is stable on the hoist before raising all the way up and going underneath it to help prevent an a...

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Page 77: ...For more information refer to section 28 1 U S EPA Emission Related Limited Warranty Canada Excluded Proper maintenance is the owner s responsibility A warranty claim may be denied if among other things the owner or operator caused the problem through improper maintenance or use You must follow the instructions for fuel requirements in section 14 1 Fuel Requirements Failure to properly maintain th...

Page 78: ...Hrs 300 480 Replace oil and oil filter Check all fluid levels Fuel Water Separator 10 Hrs 300 480 Drain weekly as used A Fuel Filter 50 Hrs 6 M 1 500 2 500 Normal use with high quality fuel Replace Fuel Filter S Engine Oil and Filter 50 Hrs 6 M 1 500 2 500 Replace oil oil filter and copper washer S Air Intake System Air Cleaner Filter 100 Hrs 3 000 5 000 Inspect for debris and or oil Clean or repl...

Page 79: ...or for damaged fins or debris obstructing airflow Repair or replace as needed Inspect fan for damage Repair or replace as needed Clean external surfaces Pressure test the system A Shift Linkage 100 Hrs 12 M 3 000 5 000 Lubricate and adjust as needed S Suspension 100 Hrs 12 M 3 000 5 000 Lubricate leaf spring pivots S Turbo Oil Lines 100 Hrs 3 000 5 000 Inspect for leaks or loose fittings Repair as...

Page 80: ...eeded A S Brakes 100 Hrs 12 M 3 000 5 000 Clean and inspect Replace as needed S Tire Rotation 3 000 5 000 See Section 23 17 for rotational pattern A Clutch Fluid 300 Hrs 36 M 9 000 15 000 Replace fluid S Axle Gear Lube 300 Hrs 36 M 9 000 15 000 Replace fluid S Power Steering Fluid 300 Hrs 36 M 9 000 15 000 Replace fluid S Transfer Case Oil 300 Hrs 36 M 9 000 15 000 Replace fluid S Transmission Oil...

Page 81: ... S For a ROXOR subjected to Severe use perform the maintenance procedure more frequently than the recommended intervals S Engine Mounts 60 M Inspect for wear or damage Replace as needed A Valve Timing Clearance n a self adjusting hydraulic lash A S Auxiliary Parking Brake As needed Lubricate and adjust as needed Headlight Aim As needed Adjust as needed A Wheel Alignment Toe Adjustment As needed Ad...

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Page 83: ...position before tightening the clamps Hoses and lines must not be subjected to any twists or stress Ensure that all clips and supports are replaced Never run the engine in an enclosed area Exhaust contains carbon monoxide which can cause loss of consciousness or death in a very short time Check to make sure the engine is off and parking brake set before jacking up the vehicle Never go under the ve...

Page 84: ...ads rotors calipers drums brake lines and master cylinder The wheels and tires should be removed to perform this procedure properly Refer to section 21 Lifting and Supporting for instruction 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Clean and inspect the pads for wear damage and looseness 4 Clean and inspect the brake discs and drums f...

Page 85: ...ne clean the cap prior to removal then add brake fluid until the fluid level is near the MAX line 5 After reinstalling cap apply pressure to the brake pedal for a few seconds next check for fluid leakage around the six main components and their fittings After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it ...

Page 86: ... out 3 If oil is not dripping out oil level is below the required level 4 Add recommended oil until it begins dripping out 5 Install and tighten the oil level plug 23 6 Check Engine Coolant Level and Leak Check The engine coolant level should be checked when the engine is at ambient room temperature Maintain the coolant level between the HIGH and LOW lines on the coolant overflow bottle Refer the ...

Page 87: ...ied Your ROXOR authorized dealer can provide the correct replacement part 23 7 Check Engine Oil Level and Leak Check The oil dipstick is located on the passenger side of the engine Engine oil should be checked on a level surface with engine cold or allow time for the oil to drain back into the oil pan before checking level to prevent overfilling 1 Position the ROXOR on a flat level surface 2 Stop ...

Page 88: ...ift the hood then place prop rod 4 While engine idles and with power steering cap on turn the steering wheel lock left to lock right a couple of times 5 Turn the engine off 6 Check the power steering fluid level in the reservoir 7 The fluid level should be maintained between the MIN and MAX lines on the side of the power steering fluid reservoir Refer to the below image 8 If fluid is low add fluid...

Page 89: ...s regarding your tires please refer to the tire warranty and literature supplied by the tire manufacturer You may also contact the tire manufacturer or MAgNA directly Improperly inflated tires can adversely affect handling or fail unexpectedly resulting in an accident and or personal injury Always inflate to the recommended tire pressure Never overload your ROXOR Overloading can result in tire fai...

Page 90: ... whether oil is dripping out 3 If oil is not dripping out oil level must be below the required level 4 Add specified oil to bring it up to the level that it starts dripping out 5 Install and tighten the oil level plug 23 11 Drain Fuel Water Separator A Water In Fuel indicator light is provided in the multifunction gauge on the dash panel Follow the steps below to drain the fuel water separator and...

Page 91: ...Lubricate the shift linkage as needed when shifting becomes difficult after excessive water exposure to the undercarriage or when there is excessive exposure to the effects of salt air Apply a quality Fluoropolymer penetrating lubricant or PTFE lubricant to shift linkage pivot points Refer to the below image 23 13 Accessory Drive Belt Tension Replacement Inspect the accessory drive belts periodica...

Page 92: ... and parking brake set 3 Loosen the pivot bolt and lock bolt nut 4 If replacing belt move the component toward the engine to remove the old belt 5 Tension belt by moving component away from engine with adjustment screw or pry bar Belt should have about to 6 35 to 12 7 mm of deflection when pushed between longest belt span 6 Tighten locking bolt nut and pivot bolts Maintenance Procedures ...

Page 93: ...ter housing clamp up and out of the way 5 Separate the lower air filter housing from the upper air filter housing 6 Gently remove the air filter by pulling straight out Refer to the below image Operating a turbo diesel engine with a soiled or damaged air filter can result in engine damage Do not attempt to wash the filter Always replace a soiled or damaged filter with a new filter 7 Clean any dirt...

Page 94: ...ommended to remove and replace the copper sealing washer The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug and a new copper sealing washer Torque between 30 40 Nm 9 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it Refer to the below image 10 Using a clean ...

Page 95: ...ng the level to the upper mark on the dipstick Do not overfill 20 Reinstall the fill cap Reinstall the dipstick 21 Dispose of used filter and oil properly 23 16 Replace Transfer Case Oil 1 Clean the oil level plug drain plug and surrounding area 2 Place a container to collect oil under the transfer case 3 Remove the lower oil drain plug Refer to the below image 4 Remove the upper oil level plug 5 ...

Page 96: ...e Wheels and Tires When rotating the tires make sure the ROXOR is on level ground and properly supported Never place your body or limbs underneath the ROXOR when supported Follow the rotational pattern below Refer to the below image Maintenance Procedures ...

Page 97: ...ong detergent degreasing agent paint thinner acetone etc 24 3 Metal and Rust Prevention Cover nicked scratched or damaged areas with touch up paint or other suitable rust inhibitor to prevent rust Keep body drain holes free from packed dirt Apply anti corrosion spray to the underbody to avoid rusting and corrosion especially for vehicles in coastal areas High pressure water can wash the grease fro...

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Page 99: ...Number The engine identification number is a 10 digit number located on a machined pad on the front driver s side of the engine block Refer below image 25 3 Noise Emission Control System Tampering with the noise emission control system is prohibited U S Federal laws and Canadian provincial laws may prohibit the following acts or the causing there of removal or rendering inoperative by any person o...

Page 100: ...oval or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases Removal or alteration or the puncturing of any part of the intake system Replacing any moving parts of the ROXOR or parts of the exhaust or intake system with parts other than those specified by the manufacturer Any other act prohibited by the clean air act and its exacting re...

Page 101: ...S 116 DOT 4 DOT 3 Opt 0 95 qts 0 90 L Manual Transmission Fluid GEAR OIL SAE 80W 90 API GL 5 2 1 qts 2 0 L Transfer Case Fluid GEAR OIL SAE 80W 90 API GL 5 1 7 qts 1 6 L Front Differential GEAR OIL SAE 80W 90 API GL 5 1 9 qts 1 8 L Rear Differential GEAR OIL SAE 80W 90 API GL 5 1 9 qts 1 8 L Power Steering Fluid ATF TYPE III H DEXRON III or equivalent 0 63 qts 0 60 L Leaf Spring Pivots NLGI 3 Mult...

Page 102: ... 91 m Ground Clearance 9 22 9 cm Fuel Capacity 16 gal 60 6 l Turning Radius 20 Vehicle Payload Capacity 1525 lbs 692 kg Towing Capacity 3500 lbs 1588 kg Engine Type Turbo Diesel Cylinders 4 4 Stroke Compression Ignition Displacement 2 7L 166 7 Cu In Bore and Stroke 3 5 x 4 33 88 9 x 110 mm Power 55 HP 2300 Torque 144 ft lbs 1400 rpm Compression Ratio 18 7 Cooling System Liquid Specifications ...

Page 103: ...d Suspension Chassis Type Box Steel Frame 10 ga Front Suspension Leaf Spring w Shock Absorbers Stabilizer Bar Rear Suspension Leaf Spring w Shock Absorbers Shock Absorbers Double Acting Hydraulic Dual Hydraulic Vacuum Assist Standard Parking Brake Standard Front Brakes 11 Disc Rear Brakes 11 Drum Features Steering Hydraulic Power Instrumentation Single Gauge Lighting HeadLights Halogen Battery 600...

Page 104: ...0 Amp Maximum Power Port 12V Standard Storage 2 Seat Boxes Tires 235 70R16 Wheel Steel 16 5 x 5 5 Lug Wheel Aluminium Optional 16 5 x 5 5 Lug Performance Maximum Speed 52 mph rpm limited Maximum Towing Speed 15 mph Country of Final Assembly USA Specifications ...

Page 105: ...nded fuel Replace with fresh recommended fuel Water or fuel in crankcase See your local ROXOR dealer for assistance Troubleshooting Table Possible Causes Solution Low battery voltage Recharge the battery Mechanical failure See your local ROXOR dealer for assistance Defective fuel pump Inspect and or replace Engine Runs Irregularly Stalls or Misfires Poor or incorrect fuel Replace with recommended ...

Page 106: ...tween turbocharger intake manifold Check for leaks in the air intake system repair leaks check o rings clamps hoses Air intake restriction Inspect and or replace air filter Troubleshooting Table Possible Causes Solution Excess Oil Consumption Clogged air filter Inspect and or replace air filter Obstruction in crankcase ventilation Locate and remove the restriction Intake manifold mounting face lea...

Page 107: ...is MANUFACTURER S WARRANTY COVERAGE The heavy duty off road engines are warranted for the period of 5 years or 3000 hours If any emission related part on your engine is defective the part will be repaired or replaced by MAgNA OWNER S WARRANTY RESPONSIBILITIES As the off road engine owner you are responsible for the performance of the required maintenance listed in your owner s manual MAgNA recomme...

Page 108: ...nd sub assemblies found to be defective with respect to materials or workmanship at no cost to you including engine exhaust system related diagnosis labor and parts The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of MAgNA Emission control system parts components covered by the Federal and California Emission Control Systems L...

Page 109: ... of Nitrogen Nox controls Selective Catalytic Reduction SCR Catalyst Reductant urea Containers Dispensing Systems NOx Sensor SCR Temperature Sensor Any Sensor for Diesel Exhaust Fluid 8 Miscellaneous Items Closed Breather System Hoses Clamp Fittings Tubing whose failure affects exhaust emissions Gaskets Seals MAgNA supplied engine Wiring Harnesses MAgNA supplied engine Elec Connectors Air Cleaner ...

Page 110: ... in this written warranty are not intended to limit modify take away from disclaim or exclude any warranties set forth in the operation of The Consumer Products Warranties Act 1977 Saskatchewan the Consumer Protection Act Quebec or any other similar provincial or federal legislation Your ROXOR authorized dealer has ensured that all systems and components of your ROXOR are operating according to ma...

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Page 113: ...ted purposes MAgNA and its partners may also use its customer data to distribute marketing and promotional information about MAgNA and related products To verify and correct your data or to be removed from the distribution list for direct marketing please contact us Mahindra USA Inc d b a MAgNA 9020 Jackrabbit Road Houston TX 77095 Main 877 449 7771 Privacy Information ...

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Page 115: ...re to follow the steps below 1 Reach out to your local dealer If you do not know who your local dealer is Go to roxoroffroad com then Locate a dealer Contact 877 449 7771 and provide your zip code 2 The dealer will need Serial number Name of owner Address Possible photo of serial number plate Bill of sale maybe required Change of Address Ownership ...

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Page 117: ... MAgNA or a ROXOR authorized dealer You will be ask to provide your Name Address Phone Number the Product Identification Number PIN and the Date it was stolen Refer to section 29 Contact Us for MAgNA addresses and phone numbers Vehicle Serial Number Engine Serial Number Insurance Information Local Dealership Contact Date of Purchase Stolen Units ...

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Mahindra ROXOR HDUV 2023, Operator'S Manual

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