Motrec G-320 Operator And Maintenance Manual Download Page 1

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G-320

OPERATOR AND MAINTENANCE MANUAL

SPARE PARTS LISTS INCLUDED

SERIAL NUMBER : 1040233 & UP

Printed in Canada

Summary of Contents for G-320

Page 1: ...G 320 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1040233 UP Printed in Canada...

Page 2: ...ly The vehicle will be returned at the owner s expense The Warranty Claim Forms must be completed and returned with the defective part s to MOTREC within 30 days after repair was done No compensation...

Page 3: ...FRONT AXLE AND STEERING 15 SAFETY PRECAUTIONS 16 ENGINE INFORMATION 19 OIL AND FUEL RECOMMANDATIONS 20 OPERATING INSTRUCTIONS 22 MAINTENANCE INSTRUCTIONS 24 WARRANTY 29 SPARE PARTS 32 BODY 33 DIFFERE...

Page 4: ...Instructions 4 INSTRUCTIONS...

Page 5: ...cle Keep both hands on steering wheel Do not exceed the vehicle cargo load capacity and gross trailing weight capacity rated for flat hard even surface Different operating conditions such as loose ter...

Page 6: ...an incline Before leaving vehicle set FWD REV shifter to NEUTRAL set parking brake remove key Accelerator and brake pedals The accelerator and brake pedals operate the same way as the pedals of an au...

Page 7: ...Maintenance 7 MAINTENANCE...

Page 8: ...eep clear from hot parts of exhaust system Avoid increasing engine RPM and vehicle speed to prevent accident and severe injuries Follow the maintenance instructions applicable to the type of repair ma...

Page 9: ...vehicle It is of the utmost importance that theses decals markings remain unaltered and readable Else the sticker or the part baring the marking has to be replaced Dashboard security warning label Gen...

Page 10: ...l if appl 5 Check radiator coolant level if applicable 2 Check master cylinder fluid level DOT 3 2 Check brake pedal travel 1 Turn front wheels straight check steering play 1 Check parking brake requi...

Page 11: ...Maintenance 11 OIL GRADE CHART Vehicle system Oil grade Engine 10W30 Differential SAE30 Brakes DOT 3 concurring with DMVSS116 standard...

Page 12: ...adjustment screw of the detent ball of the shift rod check if the shift rod has been damaged F R LEVER ADJUSTMENT If the F R cable have been disassembled put the F R selector and differential shifter...

Page 13: ...adjustment screw located on the engine figures below IMPORTANT If engine does not run smoothly at idle speed refer to engine manufacturer s instructions ENGINE MAXIMUM RPM Check engine maximum speed w...

Page 14: ...s soft or spongy air may have entered the hydraulic system and the brake system has to be bled 1 fill the master cylinder with brake fluid DOT 3 2 bleed front callipers one at a time by having someone...

Page 15: ...from either side Align the front wheel straight Install the pitman arm TOE IN ADJUSTEMENT With the wheels in straight forward direction measure the inside left to right distance between the front tire...

Page 16: ...IH XS MRHMGEXI XLI TVIWIRGI SJ E LE EVH XLEX SV GEYWI TIVWSREP MRNYV SV TVSTIVX HEQEKI MJ XLI EVRMRK MW MKRSVIH 238 2SXI MW YWIH XS RSXMJ TISTPI SJ MRWXEPPEXMSR STIVEXMSR SV QEMRXIRERGI MRJSVQEXMSR XL...

Page 17: ...QEHI JVSQ TVIGMWMSR JSVQYPEXIH GEWX MVSR IGEYWI XLI G PMRHIV PMRIV GER FI VIFSVIH XLIWI IRKMRIW GER PEWX IZIR PSRKIV IRKMRIW LEZI 43 6 36 PMRHIVW 8LIWI G PMRHIVW EVI TPEXIH MXL RMGOIP WMPMGSR XS KMZI...

Page 18: ...VIUYMVIH IZIV LSYVW XS VIQSZI XLI EGGYQYPEXIH HITSWMXW YEP JYIPIH IRKMRIW GER YWI GSRZIRXMSREP SMP MXLSYX VIUYMVMRK WTIGMEP EHHMXMSREP ZEPZI WIVZMGI 3MP 8 TI 9WI LMKL UYEPMX SMP SJ 4 QIVMGER 4IXVSPIYQ...

Page 19: ...IV JVSQ TVIZMSYW WIEWSR XS QMRMQM I KYQ HITSWMXW MR SYV JYIP W WXIQ ERH XS MRWYVI IEW WXEVXMRK S RSX EHH SMP XS XLI KEWSPMRI S RSX SZIVJMPP XLI JYIP XERO 0IEZI VSSQ JSV XLI JYIP XS I TERH YIP 8 TI SV...

Page 20: ...RHMXMSR EVQ FEXXIV LEW QYGL QSVI WXEVXMRK GETEGMX XLER E GSPH FEXXIV RKMRI HIRXMJMGEXMSR 2YQFIVW LIR SVHIVMRK TEVXW SV MR ER GSQQYRMGEXMSR MRZSPZMRK ER IRKMRI EP E W KMZI XLI 1SHIP 7TIGMJMGEXMSR ERH 7...

Page 21: ...JYIP 8YVR SJJ MKRMXMSR W MXGL J IRKMRI MPP RSX FI VIWXEVXIH JSV WSQI XMQI EPWS GPSWI JYIP ZEPZI EX 04 XERO G 8S WXST XLI IRKMRI JVSQ KEWSPMRI STIVEXMSR MX WLSYPH FI VYRRMRK FIX IIR LEPJ ERH JYPP XLVS...

Page 22: ...JP LIIP WGVIIR SV SXLIV GSSPMRK EVIEW WXST XLI IRKMRI MQQIHMEXIP ERH GPIER 3TIVEXMRK XLI IRKMRI MXL FPSGOIH SV HMVX EMV MRXEOI ERH GSSPMRK EVIEW GER GEYWI I XIRWMZI HEQEKI HYI XS SZIVLIEXMRK 62 2 SX...

Page 23: ...I SMP 238 8S TVIZIRX I XIRWMZI IRKMRI IEV SV HEQEKI EP E W QEMRXEMR XLI TVSTIV SMP PIZIP MR XLI GVEROGEWI 2IZIV STIVEXI XLI IRKMRI MXL XLI SMP PIZIP FIPS XLI w0x QEVO SV SZIV XLI w x QEVO SR XLI HMTWX...

Page 24: ...VI SMP 6IMRWXEPP XLI SMP JMPP GET ERH XMKLXIR WIGYVIP 6IMRWXEPP HMTWXMGO 238 8S TVIZIRX I XIRWMZI IRKMRI IEV SV HEQEKI EP E W QEMRXEMR XLI TVSTIV SMP PIZIP MR XLI GVEROGEWI 2IZIV STIVEXI XLI IRKMRI MX...

Page 25: ...IRXW LIGO XLI EMV GPIERIV HEMP SV FIJSVI WXEVXMRK XLI IRKMRI LIGO JSV E FYMPHYT SJ HMVX ERH HIFVMW EVSYRH XLI EMV GPIERIV W WXIQ IIT XLMW EVIE GPIER PWS GLIGO JSV PSSWI SV HEQEKIH GSQTSRIRXW 6ITPEGI E...

Page 26: ...PMRK JMRW ERH SV GSSPMRK WLVSYHW VIQSZIH MPP GEYWI IRKMRI HEQEKI HYI XS SZIVLIEXMRK KRMXMSR 7 WXIQ 8LMW IRKMRI MW IUYMTTIH MXL ER IPIGXVSRMG MKRMXMSR W WXIQ 3XLIV XLER TIVMSHMGEPP GLIGOMRK VITPEGMRK X...

Page 27: ...IEPIV SRP 7II MKYVI 0S HPI 7TIIH HNYWXMRK 7GVI 04 6IKYPEXSV R GSQTPMERGI MXL KSZIVRQIRX IQMWWMSR WXERHEVHW XLI VIKYPEXSV MW TVIWIX EX XLI JEGXSV XS TVSZMHI XLI TVSTIV WYTTP SJ JYIP 2S EHNYWXQIRX SV V...

Page 28: ...V GPIERIV IPIQIRX MW GPIER ERH EPP EMV GPIERIV IPIQIRX GSQTSRIRXW EVI JEWXIRIH WIGYVIP y LIGO JSV PSSWI OMROIH SV GVEGOIH ZEGYYQ PMRIW GEYWMRK VIKYPEXSV RSX XS STIR y LIGO XS QEOI WYVI XLI JYIP ZEPZI...

Page 29: ...KEWSPMRI QYWX FI XVIEXIH MXL E WXEFMPM IV XS TVIZIRX HIXIVMSVEXMSR J SY GLSSWI XS YWI E WXEFMPM IV JSPPS XLI QERYJEGXYVIV W VIGSQQIRHEXMSRW ERH EHH XLI GSVVIGX EQSYRX JSV XLI GETEGMX SJ XLI JYIP W WX...

Page 30: ...28630 7 78 17 0 1 8 66 28 98 0 8 2 0 2 2 6 2 2 2 7 8LI 9 7 RZMVSRQIRXEP 4VSXIGXMSR KIRG 4 XLI EPMJSVRME MV 6IWSYVGIW SEVH 6 ERH SLPIV S EVI TPIEWIH XS I TPEMR XLI IHIVEP ERH EPMJSVRME QMWWMSR SRXVSP 7...

Page 31: ...XVSRMG GSRXVSP YRMX MJ IUYMTTIH y EXEP XMG QYJJPIV MJ IUYMTTIH y EVFYVIXSV SV JYIP MRNIGXMSR W WXIQ y YIP QIXIVMRK ZEPZI MJ IUYMTTIH y YIP PMRIW MJ IUYMTTIH y 7TEVO EHZERGI QSHYPI MJ IUYMTTIH y MV JMP...

Page 32: ...Spare Parts 32 SPARE PARTS...

Page 33: ...321002 CAB WITH DOORS 480039 REAR VIEW MIRROR 2360320014 RIGHT DOOR 2360320015 LEFT DOOR 120003 TRIMMING 3 2368320024 PANEL BOX 2362320069 SIDE DOOR LEFT 2362320070 SIDE DOOR RIGHT 2362320063 REAR DOO...

Page 34: ...Spare Parts 34 DIFFERENTIAL...

Page 35: ...MINATOR A R 012HG134 24 PIN LOCATING 2 012HP120 25 VENT 1 070HN103 27 SCREW FLANGE HD SHORT 13 012HM110 1 29 NUT LOCK 15 012HN120 30 DETENT KIT ITEMS NOT SERVICED SEPARATELY 1 012LK133 31 SEAL OIL 1 0...

Page 36: ...CRIPTION 1 362841 PLATE CYLINDER 2 362842 BRAKE SHOE 4 362844 SPRING 5 362845 SPRING 6 362846 SPRING 7 362847 SPRING 8 362848 FITTING 9 362849 BLEEDER 10 362850 PISTON 13 362853 ADJUSTER 14 362855 BOL...

Page 37: ...e 6 362804 Lever 1 17 Cotter pin 3 32 x 1 5 7 262807 Pivot 2 18 Flat washer 5 16 1 8 242817 Lubrication fitting 1 19 2910000007 Clevis 5 16 x 1 1 2 1 9 Clevis pin 3 8 x 1 1 20 2130330001 Handbrake pul...

Page 38: ...Spare Parts 38 FRONT ASSEMBLY...

Page 39: ...2 CASTELLATED NUT 1 UNEF 17 2129000001 CLIP 57 2914364001 BUSHING 18 2134000001 FLEX HOXE 58 2916000001 U BOLT 19 2139000001 CALIPER PROTECTOR 59 2930000012 GREASE FITTING 20 2139000002 WASHER 60 3640...

Page 40: ...3 15 209128A MOVABLE FACE 1 5 203022A FACE MOVABLE 1 16 203097A SPACER 1 6 203031A BUSHING GUIDE 2 18 209138A FIXED FACE 1 7 203039A SPRING COMPR 1 19 206458A BUTTON 3 8 203023A FACE FIXED 1 21 209139...

Page 41: ...TTON ENGINE REF PART NO DESCRIPTION 1 3082005 HEAT SHIELD KOHLER ENGINE 2157300003 HEAT SHIELD B S ENGINE 2 3084002 MUFFLER KOHLER ENGINE 2157300002 MUFFLER BRIGGS STRATTON ENGINE 3 3084006 GASKET KOH...

Page 42: ...Spare Parts 42 MUFFLER REF PART NO DESCRIPTION 1 2157320001 MUFFLER KOHLER ENGINE 20 HP 2 2169322002 HEAT SHIELD KOHLER ENGINE 3 Contact manuf MUFFLER GASKET KOHLER ENGINE...

Page 43: ...0009 BALL JOINT MM12 3 6 SUSPENSION FRAME 1 2160301001 FOR 16 HP ENGINE 2160301030 FOR 20 HP ENGINE 7 NUT NC 4 8 LOCK WASHER 1 2 4 9 BOLT NC X 2 2 10 242621 SHOCK ABSORBER 2 11 BOLT NC X 3 2 12 282622...

Page 44: ...Spare Parts 44 ELECTRICAL DIAGRAM BRIGGS AND STRATTON...

Page 45: ...Spare Parts 45 ELECTRICAL DIAGRAM KOHLER...

Page 46: ...Spare Parts 46 ELECTRICAL DIAGRAM ACCESSORIES...

Page 47: ...RELAY 3064004 1 M1 STARTER 1 M2 ENGINE 1 M3 WIPER MOTOR 3113000001 1 M4 CAB HEATER 100W 3103300001 1 P1 HOUR METER 3069008 1 P2 VOLTMETER 3069007 1 P3 FUEL GAUGE 686203 1 R1 FUEL SENDER 686207 1 S1 IG...

Page 48: ...4 683033 RUBBER MOUNT 3 5 683032 FLAT WASHER 1 6 2154321001 ENGINE BASE 1 7 2160301022 B S ENGINE MOUNT 1 2160301027 KOHLER ENGINE MOUNT 8 B S OR KOHLER ENGINE 1 9 2169321002 ACCELERATOR CABLE BRACKET...

Page 49: ...Y 1 2105003 KNOB 1 2 2179301009 ROD SELECTOR F R 1 3 247019 SPRING 1 4 2179301001 F R SELECTOR 1 5 GREASE FITTING 1 6 7 3282024 CLEVIS YOKE 2 8 NUT NF 2 9 CABLE SPECIFY LENGTH 1 12 3282020 CABLE STOP...

Page 50: ...lamp Grommet 3269001 12V 3669012 24V 3669012A Clear lamp 12V 3069012 Bulb 12V 1269008 Pedestral head lamp 12V 2569001 Bulb 12V 2569001B Bulb 24V 4469001 Headlight Left 3111480003 Right 3111480004 Bul...

Page 51: ...86211 Wiper arm 2800000001 Wiper blade 14 Blade 2800000002 18 Blade 2800000003 Pantograph wiper arm 246233A Pantograph wiper blade 246233 Cab heater 12V 3103300001 36V 3669008 48V 4869020 12V Dome lig...

Page 52: ...15 2004 REPLACES FORM MS 9691 09 08 2003 FILE IN SECT 2 OF SERVICE MANUAL 303400 Illustrated Parts List Model Series 303400 TYPE NUMBERS 0021 through 1450 TABLE OF CONTENTS Air Cleaners 9 Alternator...

Page 53: ...ding text may not be used on your specific engine 9691 2 Assemblies include all parts shown in frames 03 15 2004 2 32 27 26 25 28 29 27 27 17 357 146 741 377 572 601 10 706 8 15 3 15 718 1058 OWNER S...

Page 54: ...ne 9691 3 Assemblies include all parts shown in frames 03 15 2004 3 812 276A 1022 338 1022 830 1100 1029 276A 40 36 383 635 337 1031 1030 1029A 6 45 1026 METAL 7A 5A 192 GRAPHOIL 7 871 601 868 522 918...

Page 55: ...es Parts shown without corresponding text may not be used on your specific engine 9691 4 Assemblies include all parts shown in frames 03 15 2004 4 276 22 552 691 615 552A 51A 51A 50 54 415 122 51C 415...

Page 56: ...hown without corresponding text may not be used on your specific engine 9691 5 Assemblies include all parts shown in frames 03 15 2004 5 287A 842 287 525A 524 525 273 650 39 596 468 479 1017 816 565 9...

Page 57: ...fic engine 9691 6 Assemblies include all parts shown in frames 03 15 2004 6 51A 868 GRAPHOIL 7 276 524 1022 883 METAL 7A 1095B VALVE GASKET SET 812 6 338 142A 104 102A 1091 121B CARBURETOR OVERHAUL KI...

Page 58: ...gines Parts shown without corresponding text may not be used on your specific engine 9691 7 Assemblies include all parts shown in frames 03 15 2004 7 868 273 20 12 3 GRAPHOIL 7 9 51A 163 163B 276 439...

Page 59: ...d on your specific engine 9691 8 Assemblies include all parts shown in frames 03 15 2004 8 95 130A 117B 105A 133A 104 629 633 217 217 102A 142A 231 276B 119 118 947A 94 97B 91 109B 955A 125B 109A 98 9...

Page 60: ...used on your specific engine 9691 9 Assemblies include all parts shown in frames 03 15 2004 9 467B 968C 167 643A 967C 445B 163B 163 11 11A 862E 833B 862D 1004B 833 875 971A 996C 711B 968B 971B 862 83...

Page 61: ......

Page 62: ...not be used on your specific engine 9691 11 Assemblies include all parts shown in frames 03 15 2004 11 300B 884 436C 725C 863B 355 819C 819D 300D 355A 819A 863 437 884 613 677B 346 882 883 436 300 300...

Page 63: ...12 Assemblies include all parts shown in frames 03 15 2004 12 601B 674A 190 674B 182E 1054 725 527 240 674B 182 1139 788 628 387 387A 385 240B 1054A 210 467 958B 968E 450 190A 674 601A 957 187 958 97...

Page 64: ...ic engine 9691 13 Assemblies include all parts shown in frames 03 15 2004 13 561 271 203 205 227 562 505 529A 629 703 1148 226 234 689 432 280 216 262 843 206 209 188 1012 222A 271B 270 269 268 188 22...

Page 65: ...Parts shown without corresponding text may not be used on your specific engine 9691 14 Assemblies include all parts shown in frames 03 15 2004 14 349 638 322A 732A 727 732 37 78 197 573 197 865A 447...

Page 66: ...xt may not be used on your specific engine 9691 15 Assemblies include all parts shown in frames 03 15 2004 15 450 305B 1046 1122 739 1036 EMISSION LABEL 304 ADAPTER WELDNUT LOCATION If Equipped 171 67...

Page 67: ...hout corresponding text may not be used on your specific engine 9691 16 Assemblies include all parts shown in frames 03 15 2004 16 695 165 23B 363 718A 1044 332 75 455 726A 23 23A 726A 726 440A 440 33...

Page 68: ...corresponding text may not be used on your specific engine 9691 17 Assemblies include all parts shown in frames 03 15 2004 17 493B 318A 65 59 55 58 57 56 515 773 456 459 608 60 318 597 949A 59A 597A 4...

Page 69: ...520A 373A 927 1048 239 878B 334 532 77 318B 493 1231 1085 373 359 520 507 578B 356A 774 506 990 879 789 813 851 664 500 356C 356D 578A 356E 356 356 507A 529A 789A 501 526 578 877C 10 16 AMP 474D NOTE...

Page 70: ...ific engine 9691 19 Assemblies include all parts shown in frames 03 15 2004 19 309 1090 1051 311 797 797A 311A 503 310B 697 803B 544B 801B 1051A 783 513 802A 797 797A 311A 697 413 310A 803A 544A 801 3...

Page 71: ...t may not be used on your specific engine 9691 20 Assemblies include all parts shown in frames 03 15 2004 20 311B 1083A 310C 803C 544C 697 801C 311B 783 513 1083A 1083 1083 403 926 802C NOTE For Repla...

Page 72: ...85 Gasket Cylinder Head Graphoil Used After Code Date 96033100 7A 807986 Gasket Cylinder Head Metal Used Before Code Date 96040100 8 808984 Breather Assembly 9 809094 Gasket Breather 10 690751 Screw B...

Page 73: ...1252 1257 1262 692165 Crankshaft Used After Code Date 97043000 Used on Type No s 1232 1293 1346 1412 1413 1421 1425 1432 807806 Crankshaft Used Before Code Date 97050100 Used on Type No s 1232 692166...

Page 74: ...Rod Connecting Standard Note 807803 Rod Connecting 020 Undersize 32 690698 Screw Connecting Rod 33 807681 Valve Exhaust 34 807680 Valve Intake 35 692084 Spring Valve Intake Used After Code Date 94011...

Page 75: ...808980 Body Upper Carburetor Used on Type No s 1381 1410 809208 Body Upper Carburetor Used on Type No s 1236 1311 1331 1334 1344 1433 1444 94 808257 Kit Idle Mixture 95 690718 Screw Throttle Valve 97...

Page 76: ...Overhaul Used After Code Date 00071100 Note 809021 Kit Carburetor Overhaul Used Before Code Date 95010100 121F 809023 Kit Carburetor Overhaul Used After Code Date 00071100 Used on Type No s 1409 1410...

Page 77: ...0725 Nozzle Carburetor Standard 142B 806860 Nozzle Carburetor Standard Used on Type No s 1320 Note 806987 Nozzle Carburetor Standard Used on Type No s 1319 1326 146 691639 Key Timing 161 691561 Base A...

Page 78: ...ing Governor Used on Type No s 0493 1193 1291 1334 692071 Spring Governor Used on Type No s 0064 0093 0132 0364 0393 0440 0443 0482 0486 1018 1052 1064 1093 1128 1142 1143 1153 1182 1186 1220 1236 127...

Page 79: ...0488 0489 0495 0496 0501 0502 0505 0518 1012 1013 1015 1017 1018 1019 1021 1025 1031 1033 1049 1054 1060 1062 1066 1073 1074 1087 1094 1111 1112 1114 1116 1118 1119 1120 1127 1129 1131 1133 1141 1158...

Page 80: ...etor Plug 278 690237 Washer Governor Control Lever 280 691526 Bracket Rod 281 690742 Panel Control 282 692083 Screw Control Lever 287 806660 Screw Dipstick Tube Special Note 692062 Screw Dipstick Tube...

Page 81: ...308G 690913 Cover Cylinder Head Cylinder 2 Black Used After Code Date 93072200 Note 807869 Cover Cylinder Head Cylinder 1 Black Used After Code Date 90111600 and Before Code Date 93072300 807657 Cover...

Page 82: ...rminal 373A 690713 Nut Ground Terminal 377 808095 Key Woodruff 383 19374 Wrench Spark Plug 385 807084 Screw Fuel Pump Note 692537 Screw Fuel Pump Used on Type No s 1434 385A 693169 Screw Fuel Pump 387...

Page 83: ...93A 691177 Bracket Mounting Regulator 493B 691503 Bracket Mounting 500 691086 Washer Key Switch 501 691185 Regulator 10 Amp Regulator 501A 691188 Regulator 5 To 9 Amp Regulated 501B 691573 Regulator 2...

Page 84: ...overnor Crank 555 692067 Screw Starter Solonoid 561 690713 Nut Control Lever 562 690239 Bolt Governor Control Lever 563 691982 Screw Debris Screen Guard 565 690682 Stud Oil Filter Adapter 572 690686 B...

Page 85: ...r Filter 650 841233 Screw Oil Deflector Used After Code Date 03120900 Note 692539 Screw Oil Deflector Used Before Code Date 03121000 691982 Screw Oil Deflector Used on Type No s 1444 663 692083 Screw...

Page 86: ...Harness Wiring Note 691578 Harness Wiring Used on Type No s 1041 1110 1278 1295 1322 1331 1384 841318 Harness Wiring Used on Type No s 1341 789A 398661 Harness Wiring Used on Type No s 1293 1412 1421...

Page 87: ...tor White Dual Socket 877B 393537 Wire Connector Altern ator Green Single Socket 877C 399916 Wire Connector Altern ator 2 Wires 7 53 64 Long 2 Bare Wire Ends And Insulated Snap ConnectMale Pin Termina...

Page 88: ...tal Mounted Oil Filter Note 808235 Adapter Oil Filter 1029 807323 Arm Rocker Used After Code Date 96033100 1029A 692103 Arm Rocker Used Before Code Date 96040100 1030 691496 Support Rocker Arm 1031 69...

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Motrec G-320, Operator And Maintenance Manual

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