mahindra pik up 26/09/12 mahindra pik up - tow bar accessory part no. - mdmahtbar0001 1. 3....

SK615 of 4

LIST OF PARTS

PART NAME

TOW BAR Assembly

Tongue

Tongue Retaining Pin

Pin Retainer - "R" Clip

D Shackle - 10mm

Tow Ball

7/8" Spring Washer

7/8" UNF Hex Nut

M10 x 30mm Hex Head Bolt

M10 Flat Washer

QTY

111121119

12

NO.

123456789

10

PART NAME

M10 Spring Washer

M10 Hex Nut

Square Spacer - 1mm Thick



Rectangular Spacer - 1mm Thick

Tongue Receiver Insert

Wiring Loom

Fitting Instructions

M10 Nylok Nut

NO.

111213141516171819

RECOMMENDED TOOL LIST1 5/16” Socket or Spanner

16 mm Socket

16mm Spanner

Torque Wrench

Phillips Head Screwdriver

12 mm Drill Bit

Electric Drill

QTY

812222111420

26/09/12

TOW BAR SPECIFICATIONS

Towing capacity braked : 2500Kg Towing capacity un-braked: 750Kg Maximum Ball Load: 250 Kg

Accessory Part No. MDMAHTBAR0001

Mahindra Pik Up (2009 Production Onwards)

TOW BARINSTALLATION INSTRUCTIONS

INSTALLATION INFORMATION

Fitment Time: approximately 30 minutesRead instructions carefully before installation.Product must be installed only with hardware supplied and as per these fitting instructions.It is recommended for this product to be installed by an Authorised Mahindra Dealer.It is advised to seek the assistance of another person when fitting this product – heavy weight.Do not use this product for any other vehicle make or model.This product or its fixings must not be modified in any way.

10 119

10 11910 119

214 1513

4

17

6

78

1

5912

14 151316

3

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FITTING INSTRUCTIONS

* *18

* : Indicates part useage that may differ from vehicle to vehicle.

SK615 26/09/12

Mahindra Pik Up - TOW BARAccessory Part No. - MDMAHTBAR0001

1.

3.

Carefully unwrap the Tow Bar, Tongue, Tow Ball, and hardware kit. Check list to ensure all components and fasteners are present.

2. With the help of an assistant, offer the Tow Bar up to the large square steel plate underneath the rear of the vehicle. Secure the Tow Bar with M10 x 30mm Hex Head Bolt, M10 Flat Washer and M10 Spring Washer at each of the four attachment points.

If the Tow Bar slots do not line up with the holes in the square steel plate on the vehicle, then the captive nuts will need to be removed from the top side of the plate. Offer the Tow Bar up to the plate and mark through the Tow Bar slots onto the chassis plate. Drill 12mm holes at these locations and then attach the Tow Bar using fasteners as per above but with an M10 Flat Washer and M10 Nylok Nut on top of the chassis plate.

Centralise the Tow Bar to the vehicle chassis and check the gaps between the Tow Bar end plates and the chassis. The gaps can be taken up with a combination of one or more of the Square Spacers in 1mm, 2mm, and 4mm thicknesses.

Secure the Tow Bar with M10 x 30mm Hex Head Bolt, M10 Flat Washer and M10 Spring Washer at each of the two attachment points on the end plates. Leave the bolts loose.


CHASSISCHASSISTOW BAR TOW BAR END PLATESEND PLATES

SPACERSSPACERS

M10 x 30mm Hex Head Bolt, M10 Flat WasherM10 Spring Washer

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1, 2, 4 mmRectangular Spacers

M10 x 30mm Hex Head Bolt, M10 Flat WasherM10 Spring Washer

Parts List

Component Name

M10 NYLOCK NUT

Item1

2

3

4

5

67

8

SK615 26/09/12

4.

6.

5.

Check to see that the Tow Bar is level with the vehicle body. If the Tow Bar is not level, one or two Rectangular Spacers will need to be added in between the Tow Bar and square pad on the vehicle. Add Rectangular Spacers to the higher side. Tighten all M10 Hex Head Bolts to 44 Nm – four underneath and two on each end plate.

Install the Tongue into the Tow Bar and secure with the Tongue Retaining Pin and Pin Retainer (“R” Clip).Secure the Tow Ball to the Tongue using the 7/8” Spring Washer and 7/8” UNF Hex Nut and tighten using a 1 5/16” Spanner or large Shifting Spanner.

Install M10 Hex Nut all the way up to the head of the M10 x 30mm Hex Head Bolt. Install the Bolt into the fixed nut in the underside of the Tow Bar and tighten until the Tongue does not rattle. hold the Bolt with a socket and tighten the hex nut up to the fixed nut to lock the bolt in place.Install D-Shackles to the safety chain attachment points.


1

3

3

1

1

1

2

2

RectangularSpacers

2

2

2

3

3

1

1

2

2

NOTE: ANTI-RATTLE BOLT SHOULD BE REMOVED WHEN TOWING A TRAILERTO PREVENT DAMAGE TO THE TONGUE

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7.

8.

Install Wiring Loom as per instructions supplied with the loom.

If Tongue is removed, the Tongue Receiver Insert can be used to plug the receiver hole. Retain using the Tongue Retaining Pin and Pin Retainer (R clip).


loom feeds along chassis rail, on to the towbar

Front of vehicle

LUMEN

LUMEN

mahindra pik up 26/09/12 mahindra pik up - tow bar accessory part no. - mdmahtbar0001 1. 3....

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