Mahindra ROXOR HDUV 2023 Operator's Manual

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Page 3 Breathing diesel engine exhaust can expose you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside. •...
Page 5: Table Of Contents
Table of Contents Introduction ................1-1 Stopping the Engine and Parking......6-4 Improvements ..............1-1 Important On-Product Labels ..........7-1 Engine tampering statement........1-1 ANSI Labels................7-1 Getting Started .................2-1 EPA Labels................7-4 Operator’s Guide ..............3-1 Manufacturer Labels............7-5 Safety Alert Symbols..............4-1 Riding Gear .................8-1 Safety Information/General Precautions ....5-1 Helmets and Eye Protection ........8-1 Additional Riding Gear ..........8-2 Avoid Carbon Monoxide Poisoning .....5-1...
Page 6 Table of Contents Additional Controls (as equipped).....11-6 Rear Cargo Area............12-3 Steering Wheel .............11-7 Tailgate ................12-3 Accelerator Pedal............11-7 Fuel Reservoir Cap .............12-4 Brake Pedal ..............11-7 13 Electrical Distribution............13-1 Clutch Pedal ..............11-8 14 Fuel (Diesel) ................14-1 Gear Shift Lever ............11-8 Fuel Requirements.............14-1 Transfer Case Lever...........11-8 Fueling Procedure ............14-1 12 Equipment................12-1...
Page 7 Table of Contents Driving on Hills and Slopes........18-3 Towing................20-2 Side Hilling ..............18-4 21 Lifting and Supporting............21-1 Drop Offs.................18-4 22 Maintenance ................22-1 Crossing Obstacles.............18-4 Severe Dusty Conditions.........22-1 Crossing Shallow Water...........18-5 Scheduled Maintenance Chart ......22-2 Crossing Public Streets, Roads, or 23 Maintenance Procedures..........23-1 Highways .................18-5 Maintenance Tips and Precautions ....23-1 Clean Spark Arrester..........23-1...
Page 8 27 Troubleshooting..............27-1 Replace Engine Air Filter ........23-11 28 Limited and EPA Warranties U.S. and Canada ..28-1 Replace Engine Oil and Oil Filter ..... 23-12 Mahindra Emissions Control Warranty Replace Transfer Case Oil ........23-13 Policy ................28-1 29 Contact Us ................29-1 Rotate Wheels and Tires ........
Page 9: Introduction
Introduction 1 Introduction 1.2 Engine tampering statement Congratulations on the purchase of your new Mahindra ROXOR Offroad Side x Side. Please know that Mahindra USA, Inc d/b/a “MAgNA” (sometimes referred to as "Mahindra" here in after) The fuel system and engine on your machine are designed and backs this unit with limited and EPA warranties.
Page 11: Getting Started
Read and make sure you fully comprehend and abide by the content 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.
Page 13: Operator's Guide
Keep this Operator’s Guide with the vehicle so you and any other operator can refer to it for things such as maintenance, troubleshooting and instructing others. To view and/or print extra copies Operator’s Guide, simply visit WWW. ROXOROFFROAD.COM. Mahindra USA, Inc. All Rights Reserved.
Page 17: Safety Information/General Precautions
ROXOR while fueling, an occupant may not be able to leave the area quickly in an emergency, failure to follow these warnings may result in severe injury or death. Mahindra USA, Inc. All Rights Reserved.
Page 18: Avoid Hot Part Hazards
MAgNA parts and accessories have been specifically designed for avoiding contact with these areas and other very hot parts, during use on the Mahindra ROXOR Offroad Side x Side. We strongly and shortly after operation. If a burn occurs from contact with...
Page 19 Dash Cluster and Engine Control Unit (ECU). Altering the Dash Cluster and/or ECU may cause driveability issues and potentially void the unit's warranty. Consult an authorized ROXOR Dealer for more information. Mahindra USA, Inc. All Rights Reserved.
Page 21: Safe Operations And Responsibilities
We also urge you to visit your authorized dealer in a timely manner if you become aware of any safety related campaigns. Mahindra USA, Inc. All Rights Reserved.
Page 22: Operator's Responsibilities
More specifically for off-road vehicles such experience, knowledge and suitable riding conditions. as the Mahindra ROXOR Offroad Side x Side, the passenger must also pay constant attention to the terrain ahead and be able to All operators must have a proper driver's license in accordance brace for bumps.
Page 23: Occupant Restraint System
Pay attention to blind spots. When it is safe to proceed in reverse, go slowly. Never exceed the stated load limits for this vehicle. Cargo must be properly secured. Reduce speed, Mahindra USA, Inc. All Rights Reserved.
Page 24: Stopping The Engine And Parking
Failure to follow these warnings may result in severe • Never operate in fast flowing water or in water deeper than injury or death. specified in section 18.10 Crossing Shallow Water Mahindra USA, Inc. All Rights Reserved.
Page 25: Important On-Product Labels
Removal of, or tampering with any of these important on-product for the safety of the operator, passengers and bystanders. They labels is highly discouraged by Mahindra. Removal of these labels need to be clean and visible at all times. If missing or damaged, may result in operators missing critical safety instructions which they need to be replaced.
Page 28: Epa Labels
They 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 Product Identification Number (PIN). Mahindra USA, Inc. All Rights Reserved.
Page 29: Manufacturer Labels
If missing or damaged, they need to be replaced. Safety labels are free of charge and can be requested from MAgNA with a registered Product Identification Number (PIN). Mahindra USA, Inc. All Rights Reserved.
Page 31: Riding Gear
Most prescription eye glasses and sunglasses will NOT underwear next to the skin also provides good insulation. Never provide proper protection while driving the Mahindra ROXOR wear any loose clothing that may get entangled in the vehicle or on Offroad Side x Side.
Page 32: Additional Riding Gear
ROXOR. For cold weather riding, avoid oversized boots that may get trapped in the foot controls and prevent the proper operation of the ROXOR. Mahindra USA, Inc. All Rights Reserved.
Page 33: Prepare To Ride
– Ensure cargo is properly secured in the rear cargo area. – Ensure maximum vehicle load capacity does not exceed specifications. This includes operator, passengers, added accessories, trailer tongue weight (if applicable), and rear cargo Mahindra USA, Inc. All Rights Reserved.
Page 34 Refer to section 26 Specifications for more information on fluid • Press on the brake pedal and make sure you feel firm resistance volumes and specifications. and it returns to the rest position when released. Mahindra USA, Inc. All Rights Reserved.
Page 35: Post-Ride Inspection Checklist
Verify that the ignition key is in the OFF position. If left in the ON position for extended periods of time electrical loads can drain the battery and cause the vehicle to not start when needed. Mahindra USA, Inc. All Rights Reserved.
Page 37: Learning Your Vehicle
(ROHVA) website (http://www. rohva. org). All operators should before operating on difficult terrain. familiarize themselves with the handling of the Mahindra ROXOR The clutch pedal is located at the far left and is required to shift Offroad Side x Side in a controlled environment before they go off- gears.
Page 38 You may also want to practice an emergency exit, which will require stopping the engine, immobilizing the ROXOR, removing the seat belt, detaching the safety net (or opening the door) and exiting the ROXOR. Mahindra USA, Inc. All Rights Reserved. 10-2...
Page 39: Vehicle Controls
All operators should familiarize themselves with all of the controls OFF position – in this position the electrical system is disabled and on the Mahindra ROXOR Offroad Side x Side, in a controlled the engine will shut off. environment, before going off-road. Find a flat area free of obstacles to practice and perform the exercises listed in section 10 Learning Your Vehicle.
Page 40 27 Troubleshooting. The ignition key should automatically return to this position when released from the start position. If this statement is not true, contact and return your ROXOR to an authorized dealer. Mahindra USA, Inc. All Rights Reserved. 11-2...
Page 41: Headlamp Switch
Tacho Meter -using the same display as the hours, this displays the engine rpm only when the engine is running. It is also displayed in a radial bar graph around the digital readouts. 11-3 Mahindra USA, Inc. All Rights Reserved.
Page 42 Check Engine Indicator – yellow light on steady or flashing when an emissions related trouble code has been set, return vehicle to an authorized Mahindra dealer for service. Water In Fuel Indicator – yellow light on steady when water reached sensor contacts in the fuel filter canister, drain water from fuel separator.
Page 44: Additional Controls (As Equipped)
There are three controls with the left-most being a 4-position dial for fan speed (OFF, Low, Medium, and High). When Heat is desired, the middle knob should be pulled out. If Air Conditioning is Mahindra USA, Inc. All Rights Reserved. 11-6...
Page 45: Steering Wheel
Grip the steering wheel with both hands, without having thumbs wrapped around the steering wheel. Hand and/or wrist injuries may occur if the thumbs are wrapped around the steering wheel. 11-7 Mahindra USA, Inc. All Rights Reserved.
Page 47: Equipment
Release the lever to called the ROPS (Rollover Protective Structure). It is designed to lock the seat into desired position. help keep the operator and passengers restrained and help provide protection to the cockpit. 12-1 Mahindra USA, Inc. All Rights Reserved.
Page 48: Shoulder Guards (As Equipped)
The passenger handhold is an integral part of the safety system and must not be removed. Removal of the passenger handhold severely increases the risk of injury or death in a rollover or any other accident. Mahindra USA, Inc. All Rights Reserved. 12-2...
Page 50: Fuel Reservoir Cap
12.13 Fuel Reservoir Cap The fuel reservoir cap is located on the right side behind the rear wheel. Refer to 14.1 Fuel Requirements or 14.2 Fueling Procedure for more on fuel related information. Mahindra USA, Inc. All Rights Reserved. 12-4...
Page 51: Electrical Distribution
13 Electrical Distribution Power Distribution Center – This component is located in the engine bay on the driver side. The Power Distribution Center cover contains a similar graphic to the one shown here for convenience. 13-1 Mahindra USA, Inc. All Rights Reserved.
Page 52 Ignition Key Switch ECU Power1 Horn Reverse Light ECU Micro Low Beam Headlight Accessory Parking Light Power Outlet 2 Speed Heater Empty – Empty – Exterior Lighting Instrument Gauge Diagnostic Port Alternator Field Excitation Mahindra USA, Inc. All Rights Reserved. 13-2...
Page 53 Electrical Distribution Relay No. Circuit Empty Intake Heater Empty R3 – R4 Starter Solenoid ECU Main Empty R7-R8 High Beam Headlight Empty Alternator Field Excitation Power Outlet LED Lightbar Accessory Exterior Lighting 13-3 Mahindra USA, Inc. All Rights Reserved.
Page 55: Fuel (Diesel)
ROXOR while fueling, an occupant may not be able to leave the area quickly in an emergency, failure to follow these warnings may result in severe injury or death. 14-1 Mahindra USA, Inc. All Rights Reserved.
Page 57: Break In Period
Bring the ROXOR to a complete stop with engine running before shifting the transfer case into 4WD Low Range to prevent gear damage and ease engagement. The ROXOR can be shifted between 2WD and 4WD High ranges at any speed. 15-1 Mahindra USA, Inc. All Rights Reserved.
Page 61: Off-Road Operation
An operator who ventures off-road should always exercise the utmost care in selecting the safest path and keeping a close eye 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.
Page 63: General Driving Techniques
ROXOR authorized dealer. When driving downhill in reverse, gravity can increase your speed above a safe level. Always use engine and gears to slow descent rate and prevent over heating the brakes. 18-1 Mahindra USA, Inc. All Rights Reserved.
Page 64: Driving In Or On Slippery Surfaces
• Hard accelerations may result in tire spin, the ROXOR to sink, eventually becoming stuck. • Use lower gears and/or 4WD Low Range to help prevent tire spin. Mahindra USA, Inc. All Rights Reserved. 18-2...
Page 65: Driving In Or On Snow Or Ice
• Always keep the transmission in gear when descending hills and which may affect the response time of the braking system, slopes and choose a gear that will help control your descent. periodically apply the brakes. 18-3 Mahindra USA, Inc. All Rights Reserved.
Page 67: Crossing Shallow Water
It is your responsibility to check your local laws related to water equipment can lead to severe injury, including death. crossings. Some rivers and streams are protected from activities like this. 18-5 Mahindra USA, Inc. All Rights Reserved.
Page 68: Group And Distance Riding
Periodically check these areas equipment and a first aid kit, and checking the local weather before, during and after your ride. report. • Find out where you can get additional fuel. Mahindra USA, Inc. All Rights Reserved. 18-6...
Page 69: Moving Loads And Doing Work
Also familiarize yourself with the weight and load limits of the Mahindra ROXOR Offroad Side x Side to avoid having a limited Use only the tie downs provided to secure a load in the rear cargo warranty claim denied due to improper use.
Page 70: Carrying Loads
Always make sure the trailer load is evenly distributed and secured. An evenly balanced trailer is easier to control. Make sure there is sufficient tongue weight to prevent a loss of traction at the rear wheels. Mahindra USA, Inc. All Rights Reserved. 19-2...
Page 73: Transporting
Never trailer the ROXOR backwards, always trailer it facing forward. The windshield (if equipped) could break away, be lost or worse become a projectile resulting in severe injury or death. 20-1 Mahindra USA, Inc. All Rights Reserved.
Page 74: Towing
25 miles and then every 100 miles after that. 1. Verify tires are inflated to 28 psi. 2. Verify vehicle alignment meets manufacturers specification. Mahindra USA, Inc. All Rights Reserved. 20-2...
Page 75: Lifting And Supporting
Front Lifting Location Verify the unit is stable on the hoist before raising all the way up and going underneath it to help prevent an accident resulting in severe injury or death. 21-1 Mahindra USA, Inc. All Rights Reserved.
Page 77: Maintenance
Air filter maintenance should be adjusted according to riding dealer, although a ROXOR authorized dealer has an in-depth conditions. Air filter maintenance must be increased in frequency technical knowledge and tools to service the Mahindra ROXOR in the following dusty conditions: Offroad Side x Side.
Page 78: Scheduled Maintenance Chart
12 M connectors. Clean and test – Propeller Shaft 3,000 (5,000) 100 Hrs 12 M • Lubricate • Inspect for corrosion or damage. Repair as needed Exhaust Pipe 3,000 (5,000) 100 Hrs 12 M Mahindra USA, Inc. All Rights Reserved. 22-2...
Page 79 100 Hrs 12 M Replace as needed • Inspect wear, loose worn connections. Repair as required Wiring 3,000 (5,000) 100 Hrs 12 M • Apply dielectric grease to connectors subjected to water, mud, etc 22-3 Mahindra USA, Inc. All Rights Reserved.
Page 80 300 Hrs 36 M Bushings needed – – Coolant 36 M • Replace fluid • Inspect for wear or noise and proper Accessory Belt(s) – – 60 M tension. Adjust or Replace as needed Mahindra USA, Inc. All Rights Reserved. 22-4...
Page 81 • Lubricate and adjust as needed Brake Headlight Aim – As needed • Adjust as needed Wheel Alignment; • Adjust as needed. Align whenever parts are As needed Toe Adjustment replaced during routine maintenance 22-5 Mahindra USA, Inc. All Rights Reserved.
Page 84: Clean And Inspect Brakes
The wheels and tires should be removed to perform this procedure properly. Refer to section 21 Lifting and Supporting for instruction. Mahindra USA, Inc. All Rights Reserved. 23-2...
Page 85: Check Brake Fluid Level And Leak Check
MAX line. 5. After reinstalling cap, apply pressure to the brake pedal for a few seconds, next check for fluid leakage around the six main components and their fittings. 23-3 Mahindra USA, Inc. All Rights Reserved.
Page 86: Check Differential Oil Levels And Leak Check
4. If low, use a funnel and slowly add coolant as needed. 4. Add recommended oil until it begins dripping out. 5. Reinstall the cap turning it clockwise. 5. Install and tighten the oil level plug. Mahindra USA, Inc. All Rights Reserved. 23-4...
Page 87: Check Engine Oil Level And Leak Check
5. Reinstall the dipstick, then remove it and check the oil level. provide the correct replacement part. 6. Maintain the oil level in the safe range, between the two notches. (Refer to the below image) Do not overfill. 23-5 Mahindra USA, Inc. All Rights Reserved.
Page 88: Check Power Steering Oil Level And Leak Check
MAX lines on the side of the power steering fluid reservoir. warranty coverage. (Refer to the below image) Clean spillage from all exposed surfaces with a clean cloth to prevent surface damage. Mahindra USA, Inc. All Rights Reserved. 23-6...
Page 89: Check Tire Pressure
MAgNA directly. Improperly inflated tires can adversely affect handling or fail unexpectedly, resulting in an accident and / or personal injury. Always inflate to the recommended tire pressure. 23-7 Mahindra USA, Inc. All Rights Reserved.
Page 90: Check
(Refer to the below image) 3. If oil is not dripping out, oil level must be below the required level. 4. Add specified oil to bring it up to the level that it starts dripping out. Mahindra USA, Inc. All Rights Reserved. 23-8...
Page 91: Lubricate Shift Linkage
It is a good idea to carry an extra belt, especially as your ROXOR ages, as broken alternator belt can leave you Clean fuel spilled on exposed surfaces with a clean cloth. stranded. 23-9 Mahindra USA, Inc. All Rights Reserved.
Page 92 Belt should have about ¼ to "½" (6.35 to 12.7 mm) of deflection when pushed between longest belt span. 6. Tighten locking bolt / nut and pivot bolts. Compressor Belt (if equipped with HVAC) Mahindra USA, Inc. All Rights Reserved. 23-10...
Page 93: Replace Engine Air Filter
10. Position the air filter housing and tighten the mounting bolt. 5. Separate the lower air filter housing from the upper air filter housing. 6. Gently remove the air filter by pulling straight out. (Refer to the below image) 23-11 Mahindra USA, Inc. All Rights Reserved.
Page 94: Replace Engine Oil And Oil Filter
Contact with hot oil can result in skin burns. Do not allow hot 12. Install the new filter and turn by hand until the filter gasket oil to contact skin. contacts the sealing surface, then turn an additional 1/2 turn. Mahindra USA, Inc. All Rights Reserved. 23-12...
Page 95: Replace Transfer Case Oil
1. Clean the oil level plug, drain plug and surrounding area. 8. Install and tighten the oil level plug. 2. Place a container to collect oil, under the transfer case. Always dispose of drained fluid properly to prevent environmental damage. 23-13 Mahindra USA, Inc. All Rights Reserved.
Page 96: Rotate Wheels And Tires
When rotating the tires, make sure the ROXOR is on level ground and properly supported. Never place your body or limbs underneath the ROXOR when supported. Follow the rotational pattern below. (Refer to the below image) Mahindra USA, Inc. All Rights Reserved. 23-14...
Page 97: Vehicle Care
ROXOR will be stored for more than 1 month. Never clean plastic parts with strong detergent, degreasing agent, Hooking up a battery tender to the battery is also recommended. paint thinner, acetone, etc. 24-1 Mahindra USA, Inc. All Rights Reserved.
Page 100: Acts Presumed To Constitute Tampering
• Any other act prohibited by the clean air act and its exacting regulations, including; modifying exhaust emissions, control devices and/ or Engine Control Unit (ECU) Mahindra USA, Inc. All Rights Reserved. 25-2...
Page 101: Specifications
ATF TYPE III H (DEXRON III or equivalent) 0.63 qts / 0.60 L Leaf Spring Pivots NLGI-3 (Multipurpose Lithium Grease) As Required Shift Linkage and Cables PTFE Lubricant As Needed U-Joints NLGI-2 As Needed Wheel Bearings NLGI-2 As Needed 26-1 Mahindra USA, Inc. All Rights Reserved.
Page 102: Vehicle Specifications
2.7L / 166.7 Cu. In. Bore and Stroke 3.5" x 4.33" (88.9 x 110 mm) Power 55 HP @ 2300 Torque 144 ft. lbs. @ 1400 rpm Compression Ratio 18.7 Cooling System Liquid Mahindra USA, Inc. All Rights Reserved. 26-2...
Page 103 Double Acting Hydraulic Dual Hydraulic Vacuum Assist Standard Parking Brake Standard 11" Disc Front Brakes 11" Drum Rear Brakes Features Steering Hydraulic Power Instrumentation Single Gauge Lighting / HeadLights Halogen Battery 600 CCA/ 12v Standard 26-3 Mahindra USA, Inc. All Rights Reserved.
Page 104 Wheel / Steel 16" - 5 x 5.5 Lug Wheel / Aluminium (Optional) 16" - 5 x 5.5 Lug Performance Maximum Speed 52 mph (rpm limited) Maximum Towing Speed 15 mph Country of Final Assembly Mahindra USA, Inc. All Rights Reserved. 26-4...
Page 105: Troubleshooting
Old or non-recommended fuel Replace with fresh fuel recommended fuel Air leak in system after Inspect for leaks and repair as Water or fuel in crankcase See your local ROXOR dealer turbocharger required for assistance 27-1 Mahindra USA, Inc. All Rights Reserved.
Page 106 (check o-rings, clamps, hoses) Engine Smokes (Black) Air leaks between Check for leaks in the air turbocharger/intake manifold intake system, repair leaks (check o-rings, clamps, hoses) Air intake restriction Inspect and/or replace air filter Mahindra USA, Inc. All Rights Reserved. 27-2...
Page 107: Limited And Epa Warranties U.s. And Canada
MANUFACTURER'S WARRANTY COVERAGE: The heavy-duty off-road engines are warranted for the period of 5 28.1 Mahindra Emissions Control Warranty Policy years or 3000 hours. If any emission-related part on your engine is defective, the part will be repaired or replaced by MAgNA...
Page 108 Federal and California Emission Control Systems Limitied Warranty are listed below (if equipped). • Cold Advance Timer • Injection Pump Components Covered : The emission-related warranty covers all components whose failure would increase an engine’s emissions of Mahindra USA, Inc. All Rights Reserved. 28-2...
Page 113: Privacy Information
To verify and correct your data, or to be removed from the distribution list for direct marketing, please contact us. Mahindra USA, Inc d/b/a "MAgNA" 9020 Jackrabbit Road, Houston, TX 77095 Main: (877) 449-7771 30-1 Mahindra USA, Inc. All Rights Reserved.
Page 115: Change Of Address/Ownership
• Contact (877) 449-7771 and provide your zip code. 2. The dealer will need • Serial number • Name of owner • Address • Possible photo of serial number plate • Bill of sale maybe required 31-1 Mahindra USA, Inc. All Rights Reserved.
Page 117: Stolen Units
Product Identification Number (PIN) and the Date it was stolen. Refer to section 29 Contact Us for MAgNA addresses and phone numbers. Vehicle Serial Number: Engine Serial Number: Insurance Information Local Dealership Contact: Date of Purchase: 32-1 Mahindra USA, Inc. All Rights Reserved.

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