Mahindra XYLO mHawk User manual

© 2012 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
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

© 2012 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.
About the Maintenance Manual
The maintenance manual outlines the correct standard operating procedures (SOPs) for carrying
out maintenance operations in a Mahindra XYLO mHawk vehicle. Carrying out the periodic
maintenance operations, as specified, is crucial for safe and trouble-free operation of the vehicle.
The recommended maintenance schedule /operations are published in the owner’s handbook.
This manual covers the correct method of carrying out the maintenance operations, using the
correct process/procedures, tools, parts and lubricants. The manual consists of –
Soft Copy - The Maintenance Manual pdf copy is presented with bookmarks. Each
Maintenance activity/ SOP is just at
one click access through the items listed in Content . To go
back to the Index page from any page of the manual, just click on word
Xylo mHawk 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), Replace (.R),
Clean (C). The maintenance periods are specified in Kilometers (Kms).
Standard Operating Procedures (SOP) – Each maintenance operation is coded by a
operation code – 712-MAT-xxxx. Here 712 stands for the model family code, MAT indicating it
is a maintenance operation and xxxx the operation number.
Each maintenance operation is explained step-by-step, in the SOP section of the manual. The
man-hours required to complete the operation is also mentioned along with the operation code.
The correct grade of lubricants /coolants to be used, torque values, special tools are also
mentioned wherever applicable.
Check Sheets – Check sheets for each service list outs the operation which need to be carried
out by the technician, when the vehicles report for scheduled maintenance service. These check
sheets need to be attached to the Repair order.
Repair Code
Repair Time {Manhours}
Job Description
Lubricant Quantity
Lubricant Recommended
Tool Specified
Torque Specified
This chart is only a sample.

© 2012 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.
Good Workshop Practices
Attire/Dress
•Always wear clean uniform
•Wear safety shoes
•Wear gloves, when required
•Wear belt cover
Vehicle Protection
•Put seat cover, fender cover, steering wheel cover, before starting the operations.
Safety
•When working with 2 or more persons, be sure to check safety for one another
•When working with engine running, make sure to provide ventilation for exhaust
fumes 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 jacking up the vehicle, be sure to support 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
replacement.
Removed Parts
•Place removed parts in a separate box to avoid mixing them up with new parts or
contaminating new parts.
•For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them
with new ones as instructed in the manual
•Retain the removed parts for customer inspection, if requested.

© 2012 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.
•Legend of the Safety Symbols
To emphasize information and procedures regarding safety, use, maintenance, etc., the
following symbols are used throughout the manual.
Term/ Symbol
Denotation
DANGER indicates an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.
WARNINGindicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
indicates a potentially
hazardous situation which, if not avoided,
may result in minor or moderate injury.
CAUTIONused without the safety alert
symbol indicates a potentially hazardous
situation which, if not avoided, may result in
property damage.
Indicates important information relevant to
the vehicle, the vehicle's use or to sections
of this manual to which particular attention
must be paid for optimum use of the
vehicle.
If you see this symbol, it indicates “no”,
“do not,” “do not do this,” or “never”.
•Legend of the Procedure/ Action Symbols
To emphasize illustrations and standard operation procedures, the following symbols are used
throughout the manual.
Symbol
Denotation
Set / Place / Check here
Locate / Show
Move forward / Fit
Rotate / Turn Clockwise
Rotate / Turn anti-clockwise

Maintenance Manual MAN-00167
XYLO mHawk February 2012/ Rev1
The repair methods given by the manufacturer in this document are based on the technical specifications,current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of 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 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., will amount to unauthorized use and shall be liable for penalty/prosecution © 2012 Mahindra & Mahindra Ltd.
Refer below Maintenance Schedule for XYLO mHawk:
Maintenance item
5000 /
4 Months
10000 /
8 Months
20000 /
12 Months
30000 40000 50000 60000 70000 80000 90000
100000 110000 120000
Engine
Engine oil
1
R I R I R I R I R I R I R
Engine oil filter R R R R R R R
Auto tensioner I I R
Accessory drive belts I I R
Coolant
3
I I I I I I R I I I I I I
Air,Fuel & Exhaust
Air filter element (In dusty conditions
replace at 30,000 Kms)
RR
Fuel filter element R RRRRR
Fuel tank & stainer C
Water 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 AAAAAAAAAA
Brakes
Brake & Clutch fluid - level & leak
check
B
I I I R I I I R I I I R
Brake pads/ Callipers I IIIIIIIIII
Brake drum and lining I IIIII
Parking brake operation A A AAAAA
Suspension
Front Suspension bolts torque I I I I I I I I
Rear Suspension bolts torque I I I I I I I I
Front suspension bushes- inspect I I I
Link bushes- inspect I I I I I
Steering
Power steering fluid - level & leak
check
I I IIIIIIIIII
Wheel alignment * Inspect if abnormal conditions are noticed or 40000kms ,whichever is earlier
Electricals
Battery electrolyte level I I I IIIIIIIIII
Battery specific gravity I I IIIIIIIIII
All Lights, Horns, Wipers & Washers I I I IIIIIIIIII
Head light aiming I
Air Conditioner
Clean mesh C C CCCCCCCCCC
Check the system for leaks and
recharge if required
Once in every 2 years
Body
Door setting A
Final inspection
Tyre pressure A A A AAAAAAAAAA
Body mounting bolts for tightness I I IIIII
Exhaust pipe mountings & damage /
leakage
I I IIIII
Road Test- if any complaints reported I I I IIIIIIIIII
Legends * On chargeable basis I = Inspect and correct
R- Replace A-Adjust C-Clean
XYLO E9
MAINTENANCE SCHEDULE
Distance Covered (in Kms) / Months in service
whichever is earlier for free service