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G-300 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER : 1035073 & UP Printed in Canada...
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To initiate warranty coverage on any MOTREC vehicle, the Dealer must complete and return the “Sales/Installation Report” to MOTREC within 30 days after delivery to the Original Retail Purchaser; or within 90 days after the delivery date to the Dealer, which ever occurs first. Failure to follow these procedures will result in considering the warranty coverage effective as of the shipment date from the factory.
Instructions SAFETY WARNINGS FOR OPERATORS • FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY. • It is the responsibility of the owner of this vehicle to train operators to ensure that they understand the operating characteristics of this vehicle, including training in vehicle stability, and obey the following safety rules and guidelines.
Instructions VEHICLE CONTROLS (B&S - KOHLER) The owner of this vehicle shall ensure that the operator understands the operating characteristics of this vehicle, and obeys the safety instructions in this manual and ANSI B56.8 & 56.9 standards. Do not drive this vehicle unless you are a qualified operator, and certified by the owner. Engine Oil Never open engine compartment while engine is running.
Maintenance SAFETY WARNINGS FOR SERVICE TECHNICIANS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY. Owner shall comply with OSHA and ASME/ANSI B56.8 & B56.9 regulations for vehicle maintenance. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect carriers, vehicles, tractors, and batteries.
Maintenance DECALS AND LABELS ! CAUTION ! The images included in this section depict the decals/markings installed on the vehicle. It is of prior importance that theses decals/markings remain unaltered and readable. Else, the sticker or the part bearing the marking has to be replaced. Dashboard security warning label: General security warning label: Respectively, key switch markings, forward/reverse selector markings and light switch marking:...
Maintenance PREVENTIVE MAINTENANCE SCHEDULE - MOTREC I.C. UNITS ! WARNING ! Read safety instructions before maintenance operations to avoid severe injury. ! WARNING ! Maintenance operations must be made by properly trained service technicians. Follow OSHA and ANSI B56 regulations.
Maintenance FORWARD/REVERSE TRANSMISSION ! ATTENTION ! Make sure that the technician disposes of the proper qualifications and training to perform the following. Before attempting to make any repairs, hoist the vehicle, immobilize and hold the vehicle in place by chocking the wheels and putting chassis stands underneath. TRANSMISSION IS HARD TO SHIFT: -check engine idle speed, it must be between 1150 and 1250 RPM;...
Maintenance ACCELERATOR ADJUSTEMENT ! ATTENTION ! Make sure that the technician disposes of the proper qualifications and training to perform the following. Before attempting to make any repairs or maintenance, hoist the vehicle, immobilize and hold the vehicle in place by chocking the wheels or putting chassis stands underneath. ENGINE IDLE RPM Check engine idle speed with accelerator released: It should read between 1150 and 1250 RPM To adjust idle speed, use the idle adjustment screw located on the pivot.
Maintenance HYDRAULIC BRAKES DRUM BRAKES Remove brake drums and check linings wear; the linings should have a thickness exceeding 1/16" (1.5 mm). Turn the brake adjustment to reduce the clearance between lining and drum but avoid contact or drag when the wheels are turned and the pedal is released. DISC BRAKES Check pad linings for excessive wear;...
Maintenance FRONT AXLE AND STEERING ! CAUTION ! Before maintenance, turn off all switches, set to neutral, set parking brake, remove the key, and raise the front end of the vehicle supporting it with two jack stands of adequate capacity STEERING INSPECTION −...
Spare Parts BODY PART NO DESCRIPTION REF PART NO DESCRIPTION 1005003 BUCKET SEAT ON SLIDE ADJUSTER 2360300004 3005003 SEAT (NOT ILLUSTRATED) 2360300005 RIGHT DOOR 3605008 SEATBACK (NOT ILLUSTRATED) 2360300006 LEFT DOOR 2380300003 SEAT PLATE 2803000003 PADDLE LATCH 2384320009 BACKREST 3602024 CATCH 2333300001 FRAME DECK 2366320001...
Spare Parts HYDRAULIC DRUM BRAKES PART NO DESCRIPTION 362841 PLATE-CYLINDER 362842 BRAKE SHOE 362844 SPRING 362845 SPRING 362846 SPRING 362847 SPRING 362848 FITTING 362849 BLEEDER 362850 PISTON 362853 ADJUSTER 362855 BOLT (GRADE 8) 3612001 LEFT LEVER 3612002 RIGHT LEVER - 36 -...
Spare Parts BRAKE CONTROLS PART NO DESCRIPTION REF PART NO DESCRIPTION Boot, included with 2910000014 Clevis pin 5/16 x 3/4 #2125000001 3016020 Lever 2910000013 Yoke 2132301001 Pivot Cotter pin 3/32 x 1 3016011 Push Rod, Master cyl. 1 Flat washer 5/16 242816 Spring 2910000007 Clevis 5/16 x 1-1/2...
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Spare Parts PART NO DESCRIPTION PART NO DESCRIPTION 2208240001 STEERING WHEEL 3040002 PLATE 481452 NUT 3/4-NF BOLT 3/8-NC X 4 481453 COVER 3040001 PLATE 481454 BOLT: 481457 BUSHING 481434 LONG 481458 TUBE 481442 SHORT ROD END: 481440 HYDRAULIC BOLT 2207000001 LEFT HAND 481441 WASHER 2207000002 RIGHT HAND...
FORM MS–9691–03/15/2004 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 ......Alternator .
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303400 718A 1019 LABEL KIT 1058 OWNER’S MANUAL 1330 REPAIR MANUAL 1025 Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–2 Assemblies include all parts shown in frames. 03/15/2004...
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303400 1023 1022 1023B 276A 1023C 1254 1023D 1023E 1022 1100 1029 1029A 276A 1031 1030 GRAPHOIL 1022 1100 276A 1029 METAL 1026 GRAPHOIL Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–3 Assemblies include all parts shown in frames.
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303400 552A 552B 616A Illustrations cover a range of engines. 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...
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303400 1028 988A 523A 1027 525C 525A 287A 1024 1017 1346 Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–5 Assemblies include all parts shown in frames. 03/15/2004...
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303400 121B CARBURETOR OVERHAUL KIT 142A 1091 105A 276B 117B 102A 121F CARBURETOR OVERHAUL KIT 142B 105A 276B 1091 117B 102A 1095B VALVE GASKET SET GRAPHOIL METAL 1022 Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–6 Assemblies include all parts shown in frames.
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303400 358A ENGINE GASKET SET GRAPHOIL 1022 163B Illustrations cover a range of engines. 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...
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303400 947A 365A 125B 108A 109A 109B 102A 142A 955A 133A 1091 105A 276B 117B 637A 130A 633C Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–8 Assemblies include all parts shown in frames. 03/15/2004...
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303400 968A 967A 711A 971B 1004 833A 833A 467A 467B 968B 968C 967B 643A 445A 643B 967C 711B 996C 971A 445B 161B 833B 163B 862D 862E 163B 1004B 862C Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–9 Assemblies include all parts shown in frames.
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303400 677B 819A 676A 819A 355A 677B 676B 863A 613A 677B 300A 884A 884A 613A 300C 819D 436A 819C 436B 436C 300D 863B 436C 725C 436D 300B Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–11 Assemblies include all parts shown in frames.
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303400 972A 7 QUART 9 QUART 957A 968E 958A 601A 958B 601B 187B 187C 187D 601B 601C 601B 385A 240B 1054A 387A 190A 674A 1139 182A 182C 182B 182E 240A 182D 674B 1054 182F 187A 182G 182J 182H 674B Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–12 Assemblies include all parts shown in frames.
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303400 ”Z” ”L” 271A 271B 222A 1012A 1012 1344 209A 211A 212A 629A 629B 529A 1148 208A 1038A 1038 Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–13 Assemblies include all parts shown in frames. 03/15/2004...
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303400 865A 732A 322A 322A 308A 308B 308G 638A 322A Illustrations cover a range of engines. 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...
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303400 1004 1046 ADAPTER 1122 305B WELDNUT LOCATION (If Equipped) 305B 1139 305C 304A PLASTIC AIR CLEANER BASE METAL AIR CLEANER BASE 1036 EMISSION LABEL Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–15 Assemblies include all parts shown in frames.
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303400 726A 726A 1044 718A 1047 668A 668A 718B 849A 440A Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–16 Assemblies include all parts shown in frames. 03/15/2004...
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303400 949A 493B 318A 608A 597A 456A 459A 689A Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–17 Assemblies include all parts shown in frames. 03/15/2004...
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303400 DUAL 5 – 9 AMP 10 – 16 AMP CIRCUIT 474B 474C 474D 877B 877C 526A NOTE: All stators use a No. 1119 mounting screw. NOTE: The proper flywheel part number and/or the alternator magnet size will de- termine the alternator type or output. See repair instruction manual for 501A additional information.
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303400 1051 309A 802A 1090 1051 311A 797A 803A 310A 544A NOTE: For Replacement Starter Motor, See Reference 309. 309B 802A 1090 510A 1051A 311A 797A 803B 544B 310B 801B Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–19 Assemblies include all parts shown in frames.
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303400 309C 802C 510B 1083 1083 311B 1083A 1083A 803C 311B 544C 310C 801C NOTE: For Replacement Starter Motor, See Reference 309. 920A 1009 309D Illustrations cover a range of engines. Parts shown without corresponding text may not be used on your specific engine. 9691–20 Assemblies include all parts shown in frames.
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 692178 Cylinder Assembly 690751 Screw 807590 Crankshaft (Used After Code Date (Breather Assembly) (Used Before Code 97043000). (Used After Code Date Date 97050100). –––––– Note –––––– 90111400). Used on Type No(s). 807521 Cylinder ––––––...
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 807745 Crankshaft 692165 Crankshaft 692169 Crankshaft (Used Before Code (Used After Code Date (Used After Code Date Date 97050100). 97043000). 97043000). Used on Type No(s). Used on Type No(s). Used on Type No(s). 0022, 0027, 0028, 1238.
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 808766 Flywheel 807900 Rod–Connecting 690754 Manifold–Intake (Steel Ring Gear) 692124 Manifold–Intake (Standard) –––––– Note –––––– Used on Type No(s). –––––– Note –––––– 808774 Flywheel 1156, 1279, 1381, 807803 (Steel Ring Gear) 1409, 1410.
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 841233 Screw 807720 Shaft–Throttle 102A 692077 Gasket–Carburetor (Rewind Starter) –––––– Note –––––– Body (Used After Code Date 841498 Shaft–Throttle 690723 Pin–Float Hinge 03120900). Used on Type No(s). 105A 805620 Valve–Float Needle ––––––...
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 807722 Shaft–Choke 121B 809022 Kit–Carburetor 809013 Carburetor 109A 808962 Shaft–Choke Overhaul (Gravity Feed Without Used on Type No(s). (Used After Code Date Solenoid) 1319, 1320, 1326, 00071100). (Used After Code Date 1409.
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 808972 Carburetor 690727 Plug–Welch 692081 Gasket–Air Cleaner Used on Type No(s). 163B 692052 Gasket–Air Cleaner 130A 690726 Valve–Throttle 1408. 133A 806961 Float–Carburetor 693148 Nut 808965 Carburetor (Ring Gear) 142A 690725 Nozzle–Carburetor Used on Type No(s).
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 807623 Adjuster–Rocker Arm 691507 805630 841233 Screw Spring–Governor Spring–Governor (Back Plate) Used on Type No(s). Used on Type No(s). (Used After Code Date 0326, 1026, 1270, 0129, 0130, 0138, 03120900). 1319, 1330, 1426.
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 691370 Strainer–Fuel 211A 692068 Spring–Governed Idle 690712 Link–Throttle 692069 Spring–Governed Idle –––––– Note –––––– 212A 691519 Link–Throttle –––––– Note –––––– 690707 690705 Link–Choke 691505 Spring–Governed Idle 806862 Spring–Choke Return Spring–Governed Idle Used on Type No(s).
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 298090 Filter–Fuel 691526 Bracket–Rod 807814 Housing–Blower 690742 Panel–Control (Black)(Without Weld 240A 691035 Filter–Fuel 692083 Screw Nut)(For Plastic Air 240B 808116 Filter–Fuel (Control Lever) Cleaner Base) 690721 Bushing–Choke Shaft 806660 Screw (Used After Code Date 692083 Screw (Dipstick...
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 841233 Screw 308A 806544 Cover–Cylinder Head 310C 692329 Screw (Blower Housing) (Cylinder 2)(Black) (Starter Motor)(5–3/8” (Used After Code Date 308B 806545 Cover–Cylinder Head Long) 03120900). (Cylinder 1)(Black) 496887 Brush Set ––––––...
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 691312 Gasket–Dipstick 19374 Wrench–Spark Plug 692154 Seal–O Ring 690661 Screw 807084 Screw (Crankcase (Fuel Pump) (Spark Arrestor) Cover/Sump) 691995 Switch–Rocker –––––– Note –––––– (Used After Code Date (Without Light) 692537 Screw 97043000).
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 691529 Plate–Pawl Friction 691185 Regulator 693172 Seal–Dipstick Tube 456A 224228 Plate–Pawl Friction (10 Amp Regulator) (Used After Code Date 808166 Pawl–Ratchet 501A 691188 Regulator 98053100). 459A 492431 Pawl–Ratchet (5 To 9 Amp ––––––...
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 526A 690717 Screw 691982 Screw 608A 808152 Starter–Rewind (Regulator)(5 To 9 (Debris Screen Guard) (Used Before Code Amp Regulated) 690682 Stud Date 93072600). (Used After Code Date (Oil Filter Adapter) ––––––...
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 806660 Screw 841233 Screw 691272 Spring–Friction (Fuel Pump Bracket) 689A 262564 Spring–Friction (Oil Deflector) 806717 Spring–Throttle Return (Used After Code Date 690680 Seal–Governor Shaft 629A 806716 Spring–Throttle Return 693109 Screw 03120900).
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 690714 Cover–Starter Drive 691996 Harness–Wiring 690297 Screw (Black) –––––– Note –––––– (Muffler Bracket) –––––– Note –––––– (Used After Code Date 691578 805503 Cover–Starter 97012300). Harness–Wiring Drive –––––– Note –––––– Used on Type No(s). (Red) 692198 Screw 1041, 1110, 1278,...
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 833A 690872 Screw 691963 Seal–Valve 695975 Kit–Housing/Cap (Air Cleaner Mounting 691116 Screw 692057 Bushing–Valve Guide Strap/Stud) (Electronic Governor 690894 Base–Air Cleaner (Used After Code Date Module) (Plastic) 97103100). 947A 692094 Solenoid–Fuel 696539 Kit–Pinion Spring 833B 691593 Screw...
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303400 REF. PART REF. PART REF. PART DESCRIPTION DESCRIPTION DESCRIPTION 806864 Seal–Throttle Shaft 1028 808033 Adapter–Oil Filter 1038 492374 Rod–Fuel Shut Off (For Horizontal 1038A 691567 Rod–Fuel Shut Off –––––– Note –––––– Mounted Oil Filter) 1044 692056 Screw 807002 Seal–Throttle ––––––...
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