Mahindra Xylo mhawk User manual

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

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.

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.

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

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

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

Refer below Recommended Lubricants Chart for XYLO mHawk -

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

XYLO mHawk (712 - MAT-xxxx)

Sr. No.

Maintenance item

Operation Code

Page No.

1 Engine oil - Replace 712 - MAT - 0001 08

2

Engine oil - Level Check 712 - MAT - 0002 09

3

Engine oil filter - Replace 712 - MAT - 0003 10

4 Auto tensioner - Inspect 712 - MAT - 0004 11

5 Auto tensioner – Replace (AC-Water pump drive

belt) 712 - MAT - 0005 12

6

Auto tensioner – Replace (Alternator-Stg. Pump) 712 - MAT - 0006 12

7

Accessory drive belts – Inspect 712 - MAT - 0007 13

8 Accessory drive belts – Replace (AC-Water pump) 712 - MAT - 0008 15

9 Accessory drive belts – Replace (Alternator-Stg.

Pump) 712 - MAT - 0009 16

10

Coolant - 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 sediments drain – Fuel filter 712 - MAT - 0015 22

16 Transmission oil – Check & Replace 712 - MAT - 0016 23

17 Differential oil (Rear) – Check & Replace 712 - MAT - 0017 25

18

Tyre rotation 712 - MAT - 0018 26

19

Brake+ Clutch fluid - level & leak Check 712 - MAT - 0020 27

20 Brake+ Clutch fluid - Replace 712 - MAT - 0021 28

21 Brake pads/ Calipers - Check 712 - MAT - 0022 32

22

Brake drum and lining - Check 712 - MAT - 0023 33

23

Parking brake operation - Check & Adjust 712 - MAT - 0024 34

24 Front Suspension bolts torque - Check 712 - MAT - 0025 36

25

Rear Suspension bolts torque - Check 712 - MAT - 0026 36

26

Front suspension bushes- Inspect 712 - MAT - 0027 37

27

Rear Suspension Link bushes- Inspect 712 - MAT - 0028 39

28 Power steering fluid - level & leak Check 712 - MAT - 0029 41

29 Wheel alignment * 712 - MAT - 0031 42

30

Battery electrolyte level - Check 712 - MAT - 0032 45

31

Battery specific gravity - Check 712 - MAT - 0033 46

32 All Lights, Horns, Wipers & Washers - Check 712 - MAT - 0034 48

33 Head light aiming - Check & Adjust 712 - MAT - 0035 56

34

HVAC Filter / Clean mesh 712 - MAT - 0036 61

35

Door setting 712 - MAT - 0037 62

36 Tyre pressure - Check & Adjust 712 - MAT - 0038 63

37

Body mounting bolts for tightness-Check & Adjust 712 - MAT - 0039 64

38

Exhaust pipe mtgs. & damage/leakage - Check 712 - MAT - 0040 65

39

Road Test- if any complaints reported 712 - MAT - 0041

40 MAINTENANCE CHECK SHEET (FOR ALL SERVICE INTERVALS) 67

*on chargeable basis.

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

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 vehicle on level ground/2 post lift /4 post lift

Engine should be hot while draining the oil.

For other than Maximile brand, the oil change interval has to be reduced to 10000kms if the

oil meets minimum of API CH-4 SAE 15W-40 specification.

Recommended intervals for Maximile Feo engine Oil change are at 5000, 20000kms & then

at every 20000kms.

Oil Drain & Refill –

1. Open the oil filler cap.

2. Place the oil collecting tray below the sump, loosen & remove the oil sump drain plug. Allow

the oil to drain for 15 min.

3. Fit the drain plug with a new gasket/ washer. Torque tightens the Drain Plug.

Torque - 27.5 ± 2.5 Nm.

4. Fill fresh oil as per the recommended quantity and specification.

5. Refit the oil filer cap & check the oil level as per procedure 712-MAT-0002.

Oil Filling Point

Page 8

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

712-MAT-0002: 0.05 hrs.

ENGINE OIL – LEVEL & LEAK – CHECK

Ensure that the vehicle is parked on level ground/2 post lift/4 post lift.

Ensure that the engine is not running.

Oil Level Check – Refer illustrations shown.

1. Pull out the dip stick gauge and wipe it clean with a cloth/paper.

2. Insert the dip stick gauge into the dip stick guide fully till the end.

3. Pull out the dip stick slowly and check for the oil level between Maximum and Minimum

level - if found below, top up with recommended oil.

4. Start the engine and check for oil leakage/ seepage at –

Refer illustration [C] checkpoints are shown with arrows.

Oil sump & crankcase joint.

Oil sump drain plug.

Oil filter mounting point.

DIPSTICK

GUIDE

MAX

MIN

DIPSTICK

A

B

C

Page 9

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

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. Recommended replacement intervals are

at 5000, 20000kms & then at every 20000kms. Use Maximile Universe oil filter.

Oil filter Removal – Refer illustrations.

1. Remove the oil filter by unscrewing it in anti-clockwise direction, using an oil filter wrench.

2. Check the oil cooler stud for tightness – Torque 27.5 ± 2.5 Nm.

3. Smear a layer of fresh engine oil on the oil filter “O” ring

4. Fit the oil filter and turn it clockwise till the “O” ring touches the oil cooler face.

5. Turn the filter another 3/4th turn by hand.

6. Check for Oil leakage/ seepage at –

Refer illustration [A] checkpoints are shown with arrows.

Oil pan & crankcase joint

Oil pan Drain Plug.

Oil filter joint.

Oil cooler joint

Oil Filter & Cooler disassembly

B

Oil Leak - Check Points near Oil Filter

A

Page 10

Mahindra XYLO mHawk User manual

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