Mahindra ROXOR, Operator'S Manual

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Page 2: ...rth defects or other reproductive harm l Always start and operate the engine in a well ventilated area l If in an enclosed area vent the exhaust to the outside l Do not modify or tamper with the exhau...

Page 3: ...SI ROHVA Labels 11 7 2 EPA Labels 15 7 3 Manufacturer Labels 17 8 Riding Gear 20 8 1 Helmets and Eye Protection 20 8 2 Additional Riding Gear 21 9 Prepare to Ride 22 9 1 Pre Ride Inspection Checklist...

Page 4: ...5 Driving in or on Snow or Ice 43 18 6 Driving on Hills and Slopes 43 18 7 Side Hilling 44 18 8 Drop Offs 44 18 9 Crossing Obstacles 44 18 10 Crossing Shallow Water 44 18 11 Crossing Public Streets R...

Page 5: ...cle Care 74 24 1 Post Operation Care 74 24 2 Vehicle Cleaning and Protection 74 24 3 Metal and Rust Prevention 74 24 4 Storage and Preseason Preparation 74 25 Technical Information 75 25 1 Product Ide...

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Page 7: ...nd EPA warranty coverages and signed the Pre Delivery Checklist to ensure your new ROXOR was prepared to your entire satisfaction Please make sure you have a copy of the Pre Delivery Checklist and ret...

Page 8: ...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 war...

Page 9: ...g 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...

Page 10: ...r a non immediate hazard presenting a lesser threat of injury resulting in minor or moderate injuries to occu pants and or general public if not avoided potential for a non immediate hazard presenting...

Page 11: ...safe to handle and store in its liquid form However diesel fuel in its vapor form can be dangerous espe cially at temperatures above 100 F 38 C The vaporization rate of diesel fuel increases as the te...

Page 12: ...your ROXOR be genuine Mahindra parts and accessories so as not to affect your safety EPA compliance or factory limited warranty Mahindra Vehicle Sales and Service Inc warrants that the Accessor ies a...

Page 13: ...with the ROXOR and its equip ment We encourage you to have an Annual Safety Inspection of your ROXOR Please contact a ROXOR authorized dealer for further details Though not required it is recommended...

Page 14: ...Occupant Restraint System The ROXOR is designed to carry one operator and one passenger both wearing proper protective gear Refer to section 8 Riding Gear for more information The operator and passen...

Page 15: ...in terrain caused by holes depressions banks softer or harder ground or other irregularities may cause the vehicle to roll over or become unstable To avoid this slow down and always observe the terra...

Page 16: ...on and release button This is especially important when parking on a slope you should always try to park on the flattest and most stable terrain available The nominal ground clearance for the ROXOR is...

Page 17: ...ply with the requirements set forth by the American National Standards Institute ANSI spe cifically standard ANSI Z535 4 2007 The ROXOR is delivered with several labels containing important safety inf...

Page 18: ...Name Pre Sale Tilt Table Information Location Center of front ROPS or rear view mirror if equipped Label Number 003AUA00100N Name Combined Tire Pressure and Overload Location Left B pillar ROPS 12 201...

Page 19: ...N Name No Passenger in Cargo Area Location Right and left seat belt retractors facing rearward Label Number 0003AUA00231N Name ROV Complies with ANSI ROHVA 1 2016 Location Right upper ROPS 2018 Mahind...

Page 20: ...7 Important On Product Labels Label Number 0003AUA00080N Name General Warning Label Location Left side of cup holder escutcheon 14 2018 Mahindra Vehicle Sales and Service Inc All Rights Reserved...

Page 21: ...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 authorized dealer with a registered Pro...

Page 22: ...Name Off Road Use Only Location Center of dash panel Label Number 0003AUA00701N Name Vehicle Emissions Control Information VECI 49 States Location Engine compartment on the radiator support 16 2018 Ma...

Page 23: ...r 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 Mahindra Vehicle Sales and Ser...

Page 24: ...Label Number 0003AUA00190N Name Shift Pattern and Transfer Case Location Dash panel Label Number 0003AUA00200N Name Dimensions and Capacities Location Dash panel 18 2018 Mahindra Vehicle Sales and Se...

Page 25: ...0251N Name Seat Belt Disconnected Location Driver s seat belt buckle end Label Number 0003AUA00261N Name Don t Do Anything Stupid Location Dash panel right side behind passenger handhold 2018 Mahindra...

Page 26: ...nap on safety shield is pre ferred 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 can not prevent all object...

Page 27: ...d 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...

Page 28: ...ed to between 71 105 Nm l Check cleanliness of radiator cooling fins l Check engine oil level Maintain between the two notches on dip stick l Check engine coolant level Maintain between HIGH and LOW l...

Page 29: ...ed l Check the fuel level l Adjust mirror s to your preferences If equipped What to do after starting the Engine l Check if steering wheel operates freely by completely turning it from side to side l...

Page 30: ...s mission exhaust and other components that can get hot during a ride l Check for fluid leaks in the engine compartment and under ROXOR l Properly park the ROXOR on the flattest surface available l Pu...

Page 31: ...mission 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 becom...

Page 32: ...th the distance required to see obstacles behind you Place an orange cone or other non destruct ible item close to the rear bumper and then pull forward until you can see the item from the driver s se...

Page 33: ...dash panel to the right of the steering wheel l ACC position in this position all lights horn radio 12V outlet and optional accessories are turned on but not the instrument cluster and engine controls...

Page 34: ...in the ON ACC position l Indicator Lights o Oil Indicator red light on steady when the oil pressure is below a safe level o Seat Belt Indicator red light on steady when the driver s seat belt is unbu...

Page 35: ...ACC position Engine intake air heater is on due to engine tem perature wait for light to go out before cranking l Fuel Gauge o 4 bars 87 or more fuel in tank o 3 bars 62 or more fuel in tank o 2 bars...

Page 36: ...ottle input will be limited if the driver s seat belt is not fastened 11 8 Brake Pedal The brake pedal is located in the middle of the three pedals on the driver s floor area Use the brake pedal slow...

Page 37: ...o prevent gear damage and ease engagement 11 11 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 between 2WD...

Page 38: ...njury or death If driver s seat belt is not fastened when the ignition is turned ON the seat belt indicator lamp will flash and the throttle input will be limited 12 2 Driver s Seat The driver s seat...

Page 39: ...They are designed to help arms and legs remain inside the cockpit Side nets can also help keep bush and debris out of the cockpit The side nets are an integral part of the safety system and must not b...

Page 40: ...perly restrained and could be ejec ted resulting in severe injury or death 12 12 Tailgate The ROXOR is equipped with a swing style tailgate The tailgate is designed to ease loading the rear cargo area...

Page 41: ...n here for convenience see Figure 2 IP Power Distribution Center This component is located behind the dash panel on the passenger side The IP Power Distribution Center cover contains a similar graphic...

Page 42: ...CU Power 20A F22 Empty F8 Engine Accessories 15A R1 Engine Auto Shut Down F9 Brake Pedal 10A R2 Starter Solenoid F10 Empty R3 FuelFeed Pump F11 High Beams 20A R4 High Beams F12 Front LED Lights 20A R5...

Page 43: ...t Gauges 10A F25 Diagnostic Connector 5A F32 Parking Lights 10A F26 High Beam Control 5A F33 Empty F27 KeySwitch 10A F34 Low Beams 15A F28 Side Rear LEDs 10A R8 Exterior Lighting F29 Horn 15A R9 Power...

Page 44: ...nd diesel injectors which 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 passenger g...

Page 45: ...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 run ning before shifti...

Page 46: ...nclines 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...

Page 47: ...ye 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 so...

Page 48: ...hat the path behind the ROXOR is free of people and or obstacles l When safe proceed with care and caution go slowly and avoid sharp turns l Always maintain a level of alertness to your blind spots wh...

Page 49: ...w down and avoid abrupt steering and throttle inputs to pre vent sliding and roll overs l Use lower gears and or 4WD Low Range to help prevent tire spin l Be aware that it may take longer to stop your...

Page 50: ...ead to severe injury or death 18 9 Crossing Obstacles l It is best to avoid obstacles whenever possible l Operator Passenger should grip steering wheel handhold firmly and keep feet on the floor durin...

Page 51: ...s designed and manufactured for off road use only l The ROXOR has been designed and validated to ANSI ROHVA standards on paved surfaces l The ROXOR is not equipped or legal to operate on public street...

Page 52: ...When group riding be aware that others in your group may not have safety equipment like turn signals or brake lights Always keep a safe distance between vehicles 18 14 Environment l Always practice t...

Page 53: ...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...

Page 54: ...jerking the load A sudden jerk on the load can damage the chain cable and or vehicles Be sure to maintain ten sion on the load throughout the hauling process When pulling another vehicle the previous...

Page 55: ...ications Use extreme caution when securing the axles do not wrap straps or chains completely around the axles so as not to dam age the brake lines resulting in severe injury or death Make sure no loos...

Page 56: ...ine if the towed vehicle needs to be licensed and plated Some states may also require brake actuation systems Instructions l Verify tires are inflated to 32 psi l Verify vehicle alignment meets manufa...

Page 57: ...st 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 see Figure 6 and the two rear locations see Figur...

Page 58: ...S EPA Emission Related Limited Warranty Canada Excluded Proper maintenance is the owner s respons ibility A warranty claim may be denied if among other things the owner or operator caused the problem...

Page 59: ...0 480 whichever comes first l Replace oiland oilfilter l Check allfluid levels Drain Water Separator 10 Hrs 300 480 l Drain regularly A FuelFilter 50 Hrs 6 M 1 500 2 500 NORMAL USE WITH HIGH QUALITY F...

Page 60: ...urfaces l Pressure test the system A Shift Linkage 100 Hrs 12 M 3 000 5 000 l Lubricate l Adjust as needed S Suspension Front Rear 100 Hrs 12 M 3 000 5 000 l Lubricate leaf spring pivots S Turbo OilLi...

Page 61: ...wer Steering Fluid 300 Hrs 36 M 9 000 15 000 l Replace fluid S Transfer Case Oil 300 Hrs 36 M 9 000 15 000 l Replace fluid S Transmission Oil 300 Hrs 36 M 9 000 15 000 l Replace fluid Spark Arrester 3...

Page 62: ...rea Exhaust contains car bon monoxide which can cause loss of consciousness or death in a very short time l Check to make sure the engine is off and parking brake set before jacking up the vehicle l N...

Page 63: ...e the brake pads rotors calipers drums brake lines and master cylinder The wheels and tires should be remove to perform this procedure properly Refer to section 21 Lifting and Supporting for instructi...

Page 64: ...9 6 If the brake fluid level is lower than the MIN level line remove the cover by pulling it straight up then add brake fluid until the fluid level is near the MAX line 7 Reinstall the cover then appl...

Page 65: ...Replace every 300 hours 36 months 9 000 miles 15 000 Km Fluid Spec GL 5 SAE 80W 90 Capacity 1 6 Quarts 1 5 Liters 1 Clean the differential oil level plugs and surrounding area a Front Oil Level Plugs...

Page 66: ...ance Interval Check regularly replace every 36 months Fluid Spec ASTM D3306 or JIS K2234 Capacity 8 5 Quarts 8 0 Liters 1 Unlatch and lift the hood then place prop rod 2 Use a rag to cover the radiato...

Page 67: ...ow time for the oil to drain back into the oil pan before checking level to prevent overfilling Maintenance Interval Check regularly replace the engine oil every 50 hours 6 months 1 500 miles 2 500 Km...

Page 68: ...rake 3 Unlatch and lift the hood then place prop rod 4 While the 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 C...

Page 69: ...res supplied by a reputable manufacturer If you ever have questions regarding your tires please refer to the tire warranty and literature supplied by the tire man ufacturer You may also contact the ti...

Page 70: ...val Check regularly replace every 300 hours 36 months 9 000 miles 15 000 Km Fluid Spec GL 4 SAE 80W90 Capacity 1 7 Quarts 1 6 Liters 1 Clean the transfer case oil level plug and surrounding area see F...

Page 71: ...aintenance Interval Check regularly drain every 10 hours 300 miles 480 Km 1 Place a catch basin under the water fuel separator 2 Turn the fuel drain petcock counter clockwise until water begins to com...

Page 72: ...Km As needed means when shifting becomes difficult after excessive water exposure to the undercarriage or excessive exposure to the effects of salt air Apply a quality Fluoropolymer penetrating lub r...

Page 73: ...nator toward the engine to loosen belt for removal 6 Remove the old belt then install the new belt 7 Tighten the adjustment nut on tension rod until the belt has about 12 7 mm of deflection when pushe...

Page 74: ...g only if the red indicator is visible the filter should be replaced see Figure 21 Maintenance Interval Check regularly replace every 100 hours 3 000 miles 5 000 Km Filter Part Number 0313AC0280N 1 Ve...

Page 75: ...pper and lower housings on re assembly 9 Reinstall the air filter housing into cradle and swing clamp into position 10 Position the air filter housing and tighten the mounting bolt Figure 21 Air Filte...

Page 76: ...r wrench turn the filter counterclockwise to remove it see Figure 24 10 Using a clean dry cloth clean the filter sealing surface on the crankcase And verify the old o ring is not stuck to the engine b...

Page 77: ...23 Maintenance Procedures Figure 23 Oil Drain Plug Figure 24 Oil Filter 2018 Mahindra Vehicle Sales and Service Inc All Rights Reserved 71...

Page 78: ...drain plug and surrounding area 2 Place a container to collect oil under the transfer case 3 Remove the drain plug 4 Remove the oil level plug see Figure 25 5 Let the oil drain out 6 Tighten the drain...

Page 79: ...s on level ground and properly supported Never place your body or limbs underneath the ROXOR when supported Follow the rotational pattern below see Figure 26 Maintenance Interval Every other oil chang...

Page 80: ...aint 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 pac...

Page 81: ...artment on the driver s side of bulkhead see Figure 27 Figure 27 Product Identification Number 25 2 Engine Identification Number On the 2 5L 152 c i Turbo Diesel m2DiCR engine provided with the ROXOR...

Page 82: ...ent of any device or element of design incorporated in the ROXOR for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or the use of the vehicl...

Page 83: ...ts 1 6 Liters Transmission Fluid GL 4 SAE 80W90 2 1 Quarts 2 0 Liters U Joints NLGI 2 EP2 Lithium Soap Grease As Needed WheelBearings NLGI 2 Lithium Complex Grease As Needed 26 2 Vehicle Specification...

Page 84: ...sorbers Shock Absorbers Double Acting Hydraulic Brakes DualHydraulic Vacuum Assist Standard Parking Brake Standard Front Brakes 11 Disc Rear Brakes 11 Drum Features Steering Hydraulic Power Instrument...

Page 85: ...ltage Recharge the battery Mechanicalfailure See your localROXOR dealer for assistance Troubleshooting Table Possible Cause Solution Defective fuelpump Inspect and or replace Engine Runs Irregularly S...

Page 86: ...tion Inspect and or replace air filter Excess Oil Consumption Clogged air filter Inspect and or replace air filter Obstruction in crankcase vent ilation Locate and remove the restriction Intake manifo...

Page 87: ...ein are authorized resellers of the ROXOR In the United States the Dealer has a direct relationship with Mahindra In Canada the Dealer has a direct relationship with the Distributor TAMPERING WITH THE...

Page 88: ...ENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANT...

Page 89: ...s and orange peel Appearances or dust and hair Contaminants may be present and visible This Limited Warranty does not cover Appearances or Contaminants l State and Local Laws Mahindra does not represe...

Page 90: ...e maintenance outlined in the Operator s Guide must be timely performed in order to maintain warranty coverage Mahindra reserves the right to make warranty coverage contingent upon proof of proper mai...

Page 91: ...t with a defect in mater ials or workmanship that would increase the engine s emissions of any regulated pollutant within the stated warranty period at no cost to the owner including expenses related...

Page 92: ...ted to the following listed components For exhaust emissions emission related components include any engine parts related to the following systems l Air Induction System l Fuel System l Ignition Syste...

Page 93: ...systems and components of your ROXOR are operating according to manufacturer s spe cifications As part of the delivery of your new ROXOR your Dealer has explained maintenance requirements operations a...

Page 94: ...d thirty 30 days The Vehicle owner should be aware that Mahindra may deny war ranty coverage if the Vehicle or a part has failed due to abuse neg lect improper maintenance or unapproved modifications...

Page 95: ...Service Inc 37 Old Brickyard Road Fletcher NC 28732 Call Center 800 292 0733 Email CustomerService roxoroffroad com Mahindra Automotive North America Manufacturing 275 Rex Blvd Auburn Hills Mi 48326 M...

Page 96: ...mar keting and promotional information about Mahindra and related products To verify and correct your data or to be removed from the distribution list for direct marketing please contact Mahindra usi...

Page 97: ...ler print a Change of Address from the ROXIT website then mail that completed form to the address listed in section 29 Contact Us In the case of a change of ownership please attach proof that the form...

Page 98: ...orized 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 Mahindra addresses and phone...

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