Mahindra XYLO mHawk Maintenance Manual Download

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2012 Mahindra & Mahindra Ltd

part, without the written permission of Mahindra & Mahindra Ltd.

MAINTENANCE MANUAL

MAN-00167

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 – FEBRUARY 2012

Summary of Contents for XYLO mHawk

Page 1: ...MAN 00167 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...

Page 2: ...existing on top left side of each page Maintenance Schedule The maintenance schedules outlines the operations to be carried out a specified interval These operations are Adjust A Inspect Correct I Re...

Page 3: ...mes in the workshop If working on high temperature high pressure rotating moving or vibrating parts you should wear appropriate safety gear and take extra care not to injure yourself or others When ja...

Page 4: ...CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situatio...

Page 5: ...sediments drain Fuel filter or when indicator glows C C C C C C C Transmission Transmission oil 2 R I R Axles wheels tyres Differential oil Rear 2 R I R I Tyre rotation A A A A A A A A A A A A Brakes...

Page 6: ...ent 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 consen...

Page 7: ...olant Check 712 MAT 0010 17 11 Coolant Replace 712 MAT 0011 18 12 Air filter element Replace 712 MAT 0012 19 13 Fuel filter element Replace 712 MAT 0013 20 14 Fuel tank Clean 712 MAT 0014 21 15 Water...

Page 8: ...ndra Ltd 712 MAT 0001 0 30 hrs ENGINE OIL REPLACE Engine oil MAXIMILE Feo Capacity 6 0 Lit Nut Bolt description Quantity Nos Spanner Size Torque Value Nm Oil Sump drain plug 01 22 mm 27 5 2 5 Park the...

Page 9: ...of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0002 0 05 hrs ENGINE OIL LEVEL LEAK CHECK Ensure that the vehic...

Page 10: ...ecution 2012 Mahindra Mahindra Ltd 712 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 change Recomme...

Page 11: ...SIONER CHECK on AC Water pump and Alternator Steering Pump drive belt Auto tensioner to be check at 60000 80000kms and it is recommended to replace it at every 100000kms Auto Tensioner Inspection Refe...

Page 12: ...ner mtg bolt Alt PSP Auto tensioner AC Comp mtg bolts 01 01 01 12 mm 8mm Allen 12 mm 25 3 32 5 2 5 25 3 AUTOTENSIONER REPLACE A Alternator Power Steering Pump Drive Belt B AC Compressor Water Pump Dri...

Page 13: ...y prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0007 0 50 hrs ACCESSORY DRIVE BELT INSPECT AC Water pump and Alternator Steering Pump drive belt ACCESSORY DRIVE BELT LAYOUT ACCESSORY DRIVE BELT TO BE...

Page 14: ...Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 5 Misalignment Sidewalls of the belt may appear glazed or the edge cord may...

Page 15: ...Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0008 0 50 hrs ACCESSORY DRIVE BELT REPLACE AC Wa...

Page 16: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0009 0 40 hrs ACCESSORY DRIVE BELT REPLACE Alternator St...

Page 17: ...Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0010 0 05 hrs COOLANT LEVEL CHECK Coolant MAXIMIL...

Page 18: ...ixed Capacity 08 Lit COOLANT REPLACE Refer illustration shown A B 1 Open the degassing tank cap 2 Place coolant collection tray below and remove the drain plug on the Radiator bottom A and Engine bloc...

Page 19: ...Nos Spanner Size Torque Value Nm Air filter top cover allen bolt Hose clamps air cleaner to manifold 07 02 02 6 mm 11 mm 11 mm 4 5 0 5 2 5 0 5 4 5 0 5 Never try to clean and reuse the Air filter cartr...

Page 20: ...zed use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0013 0 50 hrs FUEL FILTER REPLACE Engine Compartment Remove the Water in Fuel Sensor connector and remove the sen...

Page 21: ...in plug if applicable and ensure for complete fuel drain and Refit the drain plug 27 5 2 5 Nm Check the fuel quantity before removing tank from the vehicle if the drain plug is not provided More care...

Page 22: ...Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0015 0 20 hrs WATER SEDIMENTS DRAIN FUEL FILTER Water in Fuel Sensor is fit...

Page 23: ...re of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0016 0 30 hrs TRANSMISSION OIL REPLACE Transmission Oil MAXIM...

Page 24: ...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 2012 Mahindra Mahi...

Page 25: ...2 MAT 0017 0 20 hrs DIFFERENTIAL OIL CHECK REPLACE Differential Oil MAXIMILE Elite Capacity 1 8 Lit Recommended oil brand is Maximile Elite The oil change interval has to be first at 10000kms then 100...

Page 26: ...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 2012 Mahindra Mahindra Ltd 712 M...

Page 27: ...tted 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 clutch circuit In case anyone circu...

Page 28: ...ACE Clutch Brake Fluid DOT4 Standard Capacity 0 9 Lit Brake Fluid Replacement Brake Bleeding Procedure Use brake fluid DOT 4 standards only Use fresh clean fluid from a sealed container at all times A...

Page 29: ...alty prosecution 2012 Mahindra Mahindra Ltd This is Sample illustration 3 Depress the brake foot pedal and hold it down 4 Open the bleed screw The fluid will flow into the transparent container 5 Tigh...

Page 30: ...TCH BLEEDING 1 Remove the dust cap of the bleeder screw 2 Connect bleeding tube to bleeding screw on slave cylinder Ensure that the other end of the tube is fully immersed in the bottle having clean c...

Page 31: ...tle Entire bleeding operation should be done with ENGINE ON running The reservoir on the master cylinder must be at the Max upper level mark at the start of bleeding procedure and should be checked af...

Page 32: ...outboard wear indicates either bent or seized sliding pin Please check the complete hydraulic system besides the calipers Always replace the front pads and shims together as a set Install inner pad wi...

Page 33: ...ke shoes are replaced replace both RH LH assemblies as a set to prevent car from pulling to one side when braking If there is significant difference in the thickness of the liner on the left and right...

Page 34: ...nt 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 Mahind...

Page 35: ...erson 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 2012 Mahindra Mahindra Ltd...

Page 36: ...ON Lower Control Arm Front Mounting 200 Nm Lower control Arm Rear mounting 200 Nm Shock absorber Top on body 40 10 Nm Shock absorber Bottom on LCA 120 10 Nm REAR SUSPENSION Upper Link 150 10 Nm Lower...

Page 37: ...hall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0027 0 20 hrs FRONT SUSPENSION BUSH CHECK Front Suspension Bush Check Refer illustrations shown 1 Check lower control arm fron...

Page 38: ...ment 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 2012 Mahindra...

Page 39: ...thorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0028 0 20 hrs REAR SUSPENSION BUSH CHECK...

Page 40: ...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 2012 Mahindra Mahin...

Page 41: ...l at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0029 0 10 hrs POWER STEERING...

Page 42: ...ission 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...

Page 43: ...Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Pre Work for Wheel Alignment Process Tyre pressure Should be as per recomme...

Page 44: ...hindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Ride height Is the verticle distance between front camber bolt nut side end center to...

Page 45: ...orized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0032 0 10 hrs BATTERY ELECTROLYTE LEVEL CHECK Refer above illustration 1 Ensure the electrolyte level between...

Page 46: ...e a Specific gravity b Open circuit voltage Visual Inspection Battery service should begin with thorough visual inspection This inspection may reveal simple and easily correctable problems 1 Check for...

Page 47: ...specific gravity of 1 230 or higher to proceed with the load test 1 Wear suitable eye protectors goggles Remove the vent caps or covers from the battery 2 Squeeze the hydrometer bulb and insert the pi...

Page 48: ...e Low Brake Oil Warning Lamp K High Engine Coolant Temperature Warning Lamp B Turn Lamp Left L Turn Lamp Right C Check Engine Lamp M Low Engine Oil Pressure Warning Lamp D Water in Fuel Warning Lamp N...

Page 49: ...orized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Digital Drive Assist System DDAS It displays the information of current vehicle performance and environmental conditio...

Page 50: ...g lamps head lamps head lamp beam selection high beam flashing and turn signals when the ignition switch is ON Push the lighting control stalk backward direction to indicate a right turn and push the...

Page 51: ...be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Head Lamp ON Rotate the outer rotary switch on the lighting control stalk aligning the dot on the switch to the 2nd detente position on th...

Page 52: ...a Mahindra Ltd Front Rear Fog Lamp To switch ON the front and rear fog lamps switch ON the parking lamps turn the inner rotary switch on the lighting control stalk to align with the inner fixed stalk...

Page 53: ...er will start wiping Turn the wiper stalk to OFF position before wiper starts second wipe Turn the wiper stalk to position C again after the required delay and the same delay will be programmed On kee...

Page 54: ...nozzles with twin adjustable washer jets in the front on the hood Using a pin the eye ball jets can be adjusted precisely for direction Always direct the washer jet to hit middle of the windshield Th...

Page 55: ...he Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0035 0 30 hrs HEADLAMP AIMING ALIGN...

Page 56: ...the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Head Lamp Alignment Procedure STEP 1 Sett...

Page 57: ...ice Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd LH side head lamp assembled condition Rear View Rotation of t...

Page 58: ...r 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 2012 Mahindra Mahindra Ltd Check the...

Page 59: ...essories 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 Mah...

Page 60: ...ment 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 2012 Mahindra...

Page 61: ...t the centre of latch striker will foul with top or bottom portion of latch Loosen the bolts of striker and move the striker up or down to remove the fouling 2 Check whether door is over flush or unde...

Page 62: ...amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0038 0 30 hrs TYRE PRESSURE CHECK AND ADJUST Proper tyre inflation pressure is essential to t...

Page 63: ...hindra 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 pen...

Page 64: ...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 othe...

Page 65: ...ndra 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 penal...

Page 66: ...ous component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part or whole of the present document are prohibited without the prior written...

Page 67: ...or penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 REPLACE 0 30 Engine oil filter REPLACE 0 20 Coolant 3 I 0 05 W...

Page 68: ...ution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05 Water sediments drain Fuel filter or when indicator glo...

Page 69: ...STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 REPLACE 0 30 Engine oil filter REPLACE 0 20 Coolant 3 I 0 05 Fuel filter element REPLACE 0 50 Tyre rotation A 0 60 Brake Clutch fluid le...

Page 70: ...unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05...

Page 71: ...plete Incomplete Engine oil 1 REPLACE 0 30 Engine oil filter REPLACE 0 20 Coolant 3 I 0 05 Fuel filter element REPLACE 0 50 Tyre rotation A 0 60 Brake Clutch fluid level leak check B REPLACE 0 15 Brak...

Page 72: ...be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05 Water sediments drain Fuel...

Page 73: ...Engine oil filter REPLACE 0 20 Auto tensioner I 0 10 Accessory drive belts I 0 20 Coolant 3 REPLACE 0 60 Air filter element In dusty conditions replace at 30 000 Kms REPLACE 0 25 Fuel filter element R...

Page 74: ...o unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 0...

Page 75: ...er REPLACE 0 20 Auto tensioner I 0 10 Accessory drive belts I 0 20 Coolant 3 I 0 05 Fuel filter element REPLACE 0 50 Fuel tank stainer CLEAN 1 00 Differential oil Rear 2 REPLACE 0 20 Tyre rotation A 0...

Page 76: ...o unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 0...

Page 77: ...oil 1 REPLACE 0 30 Engine oil filter REPLACE 0 20 Auto tensioner REPLACE 1 20 Accessory drive belts REPLACE Coolant 3 I 0 05 Fuel filter element REPLACE 0 50 Transmission oil 2 REPLACE 0 30 Tyre rota...

Page 78: ...unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05...

Page 79: ...filter REPLACE 0 20 Coolant 3 I 0 05 Air filter element In dusty conditions replace at 30 000 Kms REPLACE 0 25 Fuel filter element REPLACE 0 50 Differential oil Rear 2 I 0 20 Tyre rotation A 0 60 Bra...

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