Mahindra Roxor 1202CUA00101N User manual

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Defrost 2 Spd No Cab
Defrost 2 Speed Heater No Cab (P/N 1202CUA00101N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 1 of 4
W O R K I N S T R U C T I O N O V E R V I E W
lRead and understand manual of die grinder before operating.
lDo not attempt to use this tool unless experienced to do so.
lBefore starting die grinder, be sure that no one is in the plane
of rotation.
lAlways wear eye protection.
lFailure to observe these warnings could result in severe injury
to yourself and or bystanders.
lDO NOT ATTEMPT THIS PROCEDURE IF YOU DO NOT HAVE
PROPER TOOLS, TRAINING, AND FACILITIES.
lRead and follow all instructions provided when installing this
product. Failure to do so may result in placing occupants at
risk of serious injury or death.
lTo protect bystanders and the service technician(s), shut
vehicle off, remove the Ignition Key and secure vehicle to
prevent unintended movement.
lNever operate the vehicle in excess of manufacturer’s
specifications.
lThis accessory is not compatible with the ROXOR Full Hard
Cab Enclosure or Vintage Heat and A/C Systems.
lWindshield removal is required for this installation, this
includes removal of any accessory that would prevent
windshield removal.
These instructions should be used for installing the Defrost for
Dual Speed Heater Kit only.
lP/N 1202BUA00130N - Heater Kit (4 Hole)
P/N 1202BUA00090N - Heater Kit (6 Hole)
T O O L S R E Q U I R E D
l10 mm Socket
l13 mm Socket
lT15 Torx
lT30 Torx
l19/64 Drill Bit
l13 mm Wrench
lSocket Driver
lStraight Edge
lDrill
lDie Grinder
lCut Off Wheel
lCenter Punch
lScissors
lProtective Eye-wear
T O R Q U E S P E C I F I C A T I O N
Tighten each fastener to the torque specification below:
lPan Screws – 2.5 N•m (±0.5 N•m)
lM6 Screws – 10 N•m (±1 N•m)
lM8 Bolts – 23.5 N•m (±3.5)
C O M P O N EN T T A B L E
Kit
Component Description Qty
Defroster Duct - Lower Distribution
PN - 1203ZUA00661N
1
Register Cover
P/N - 1203ZUA00441N
1
Defrost Duct
P/N - 1203ZUA00421N
1
Register Ball Valve
PN - 1203ZUA00641N
2
Foam - Windshield to ROPS
PN - 0107AUA00031N
1
Defrost Hose - 55 Inches
PN - 1203ZUA00761N
1
Pan Screw - 4.2X1.41X25 T15
P/N - 0000AUA01961N
2
M6 Plastic Rivet
P/N - 0105ZAW00211N
1
M4.2 U-Nut
P/N - 0000AUA00391N
2
Cable Tie Strap - 305 mm Long
P/N - 0000AUA00461N
4

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Defrost 2 Spd No Cab
Defrost 2 Speed Heater No Cab (P/N 1202CUA00101N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 2 of 4
I N S T A L L A T I O N P R O C E D U R E
1. Remove (11) M6 T30 torx screws.
2. Carefully pry out steering column cover and tape to steering
wheel.
3. Remove (3) M8 bolts, tape cover and column, disconnect
switches and remove instrument panel.
4. Using template, use suitable punch to mark (4) corners. Use
(2) locator holes for centering.
5. Using template, use center punch to mark (1) outer hole for
register cover.
6. Use straight edge to draw rectangle using punch marks.
7. Score lines lightly, then cut out top layer.

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Defrost 2 Spd No Cab
Defrost 2 Speed Heater No Cab (P/N 1202CUA00101N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 3 of 4
8. Cut out lower section. Check fitment and trim if needed.
Deburr and paint all rough areas.
9. Using (2) u-clips, install duct upward with (1) pan head screw.
Be sure it snaps into place, front to back.
10. Measure 20" and cut defrost hose. Remaining section should
be roughly 16". Left side will be longer side.
11. Affix foam around inside edge of lower distribution bowl.
12. Separate (2) register ball valves and install into (1) lower
distribution bowl.
13. Remove lower (2) M6 hex bolts from heater. Repeat for
opposite side of heater.
14. Install (1) lower distribution bowl re-using (4) M6 hex bolts.
15. If equipped, cut out wiper grommet section on register cover.

SL08_Rev01 Work Instruction Template Template Released 8 November 2018
Work Instruction: Install Defrost 2 Spd No Cab
Defrost 2 Speed Heater No Cab (P/N 1202CUA00101N)
CONFIDENTIALDOCUMENT
© 2020 Mahindra Vehicle Sales and Service, Inc. All Rights Reserved.
ROXOR is a registered trademark of Mahindra Vehicle Sales and Service, Inc.
Page 4 of 4
16. Re-install (3) M8 bolts, remove tape and re-install column
cover.
17. Using (1) M6 plastic rivet, (1) pan screw right, install register
cover, then re-install remaining (2) M6 torx screws.
18. Re-using (11) M6 screws, connect all connectors and re-install
IP.
19. Install (2) hoses to distribution bowl.

LH TEMPLATE
1: CUT ALONG LINE
2: ALIGN ARROWS A-A AND B-B
3: TAPE TOGETHER AFTER
ALIGNING ARROWS
AA
B
B
TEMPLATE 1 OF 2
MUST BE USED WITH RH TEMPLATE
1203ZUA00601N
19/64
FRONT OF VEHICLE
DEFROST CUTOUT
11
2
22
2
11

RH TEMPLATE
1: CUT ALONG LINE
2: ALIGN ARROWS A-A AND B-B
3: TAPE TOGETHER AFTER
ALIGNING ARROWS
AA
B
B
1203ZUA00601N
FRONT OF VEHICLE
DEFROST CUTOUT
11
22
1
1
22
TEMPLATE 2 OF 2
MUST BE USED WITH LH TEMPLATE