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Assembly Instructions for 1900 JONAS WC04

Step-by-step instructions for assembling the 1900 JONAS WC04 model, including diagrams, parts list, and required tools.

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Assembly Instructions for 1900 JONAS WC04

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  1. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 1DATE: 9/8/08 Authorized By: Assembly Instructions: 1900 JONAS WC – 04 (Station 4) Pages 1-26 P:\ISO 9001 2000\Work Instructions\Assembly\Main Assembly Line\JONAS 1900 AY25 Rev 1

  2. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 2DATE: 10/29/08 Shop Note: Tighten only the NUTS-HEX on the (6) 3400059 SCRS-THM. Leave NUTS-HEX on (2) 3400058SCR-TRS hand tight. 3307276 3400059 3307281 3400058 3400058 Get (1) SEAL-FRAME HOPPER SW/A (3307276), (1) STRAP-FRAME HOP FLAP PNTD SW/A (3307281), (6) SCR-THM 1/4-20 X .75 SS (3400059), (2) SCR-TRS,1/4-20X1.00,SLT ZP (3400058) and (8) NUT-HEX 1/4-20 ES ZP (3400081). Fold SEAL-FRAME HOPPER SW/A in half as shown. Insert (6) 3400059 SCRS-THM through the hopper side of strap and seal to the operator side as shown. Insert (2) 3400058 SCRS-TRS, one through 2nd hole from left side (driver’s perspective) and one through 1st hole from right side, as shown. Secure all (8) SCRS with (8) NUT-HEX. Tighten only the NUTS-HEX on the (6) 3400059 SCRS-THM. Leave NUTS-HEX on (2) 3400058SCR-TRS hand tight. Parts: 3307276 / 3307281 / 3400081 / 3400059 / 3400058 Tools: Air Ratchet / 7/16” Socket / Screwdriver

  3. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 3DATE: 9/8/08 LP UNITS ONLY 3301558 3401025 3335978 3301558 Get (1) ASSY-LPG FUEL LINE, HARD TUBE (3335891), (1) FTG-LP FILTER 46 X 6 (3401025) and (1) HOSE-LP FUEL, 5/16"ID X 11/16"OD X 77" LG (3335978). Apply 565 PST.ThrdSlnt50ml (WHITE LOCTITE 565) (3401122) to threads of right end of ASSY-LPG FUEL LINE, HARD TUBE, oriented as shown, and thread on 3401025 FTG-LP FILTER. Tighten. Thread 3335978HOSE-LP FUEL onto other end of FTG-LP FILTER 46 X 6. Tighten. Parts: 3335891 / 3401025 / 3335978 Tools: 3/4” Wrench / 11/16” Wrench

  4. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 4DATE: 9/8/08 LP UNITS ONLY Get (1) SCR-HEX, TAP 1/4-20X2.00 ZP (3401518), (1) CLAMP-FUEL LINE (3301558), (2) NUT-FLANGE LOCK 1/4-20 ZP (3400063) and (1) NUT-HEX 1/4-20 ES ZP (3400081). Place 90-degree bend end of 3335891 ASSY-LPG FUEL LINE, HARD TUBE inside center-rear of frame behind tail wheel assembly, as shown. Place other end of LPG HARD TUBE with 3335978 Hose attached inside left-rear of frame at rear of engine compartment, as shown at top right. Under 90-degree bend end of LPG HARD TUBE, insert 3401518 SCR-HEX, TAP through bottom of frame. Inside frame, thread (1) NUT-FLANGE LOCK on SCR-HEX all the way down to hold screw against frame. Thread 2nd NUT-FLANGE LOCKreversed on SCR-HEX down about ½” inch, as shown. Place CLAMP-FUEL LINE around LPG HARD TUBE on top of screw. Thread 3400081 NUT-HEX on top of clamp. Hand tighten. 3335891 3335978 3335891 3301558 3400081 3400063 3401518 Parts: 3401518 / 3301558 / 3400063 / 3400081

  5. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 5DATE: 9/8/08 3400030 / 3400087 3335978 3301158 3400087 / 3400079 3335891 Get (1) CLAMP-CABLE ¾ (3301158), (1) SCR-HEX,3/8-16X1.00 ZP (3400030), (2) WASHER-FLAT 3/8 STANDARD ZP (3400087) and (1) NUT-HEX 3/8-16 ES ZP (3400079). Inside left-rear of frame at rear of engine on other end of ASSY-LPG FUEL LINE, HARD TUBE, place CLAMP-CABLE ¾ around 3335978 Hose and secure with 3400030 SCR-HEXand 3400087 WASHER-FLAT inserted through top of frame, as shown. Secure under frame with 3400087 WASHER-FLAT and 3400079 NUT-HEX. Tighten. Route unconnected end of 3335978 Hose under frame and up on top of hoses connected to rear of engine, as shown at bottom right. 3335978 3301158 Parts: 3301158 / 3400030 / 3400087 / 3400079 Tools: 9/16” Wrench / 9/16” Socket / Air Ratchet

  6. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 6DATE: 9/8/08 Shop Note: Adjust these screws almost flush with plate. Each screw should have two threads above the plate of the ASSY-ENGINE PIVOT SUB. Adjust the ASSY-ENGINE PIVOT SUB alignment bolts almost flush with the top surface of the ASSY-ENGINE PIVOT SUB. Each screw should have two threads above the plate of the ASSY-ENGINE PIVOT SUB. Tools: 9/16” Wrench

  7. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 7DATE: 9/8/08 Get (1) SUB-ENG, DSL, 1900 (3335068) or (1) ASSY - ENGINE, GM 1.6L, LP FUEL (3335900). Hook the short chain to the front side of ENGINE in the eyelet. Hook the longer chain to the rear of the ENGINE in the eyelet. Hoist ENGINE up into position over frame. Parts: 3335068 or 3335900 Tools: 1-Ton Hoist / Chain

  8. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 8DATE: 9/8/08 Indexing pins Indexing pins Hoist the SUB-ENG to rest on the top of the ASSY-ENGINE PIVOT SUB. Align the indexing pins with the holes in the ASSY-ENGINE PIVOT SUB while lowering into position.

  9. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 9DATE: 9/8/08 3400029 / 3400101 (2) 3400029 and (2) 3400101 on this side. Get (4) SCREWS-HEX 3/8-16X1.25 ZP (3400029) and (4) WASHER-LOCK 3/8 SPLIT ZP (3400101). Mount the engine to the ASSY-ENGINE PIVOT SUB with (4) SCREWS-HEX 3/8-16X1.25 ZP and (4) WASHER-LOCK 3/8 SPLIT ZP. Parts: 3400029 / 3400101 Tools: Air Ratchet / Extension / 9/16” Socket

  10. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 10DATE: 9/8/08 Adjust the SCREWS-HEX until the SUB-ENGINE is level, both side to side and front to back. Tools: Air Ratchet / 9/16” Socket / Level

  11. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 11DATE: 9/8/08 Ball Joint SUB-ENGINE SWITCH, 1900 Swing engine in. Adjust the swing-frame latch on the SUB-ENG by turning the ball joint counter-clockwise until the latch is tight when closed with SUB-ENGINE SWITCH, 1900. Tools: ½” Wrench

  12. 3335522 MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 12DATE: 9/8/08 SUB-ENGINE SWITCH, 1900 If SUB-ENGINE SWITCH, 1900 needs to be raised to make contact with engine latch tab, open left-side broom door and remove mounting hardware. Use as many PLATE-SPACERS, ENG CATCH (3335522) as needed under each side of SUB-ENGINE SWITCH, 1900 for alignment. Engine latch tab Check position of engine latch tab inside SUB-ENGINE SWITCH, 1900. Engine Latch Tab must make contact with Whisker switch inside SUB-ENGINE SWITCH, 1900 and should be centered inside SUB-ENGINE SWITCH, 1900. Whisker switch Close engine latch again to check alignment with SUB-ENGINE SWITCH. Replace hardware on switch. Tools: Extension / Ratchet / 7/16” Socket / 7/16” Wrench

  13. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 13DATE: 9/8/08 SUB-ENGINE SWITCH, 1900 Shop Note: Check to make sure that engine latch will closetightly. After adjustment, tighten the SCREWS on the SUB-ENGINE SWITCH, 1900. Close the left-side broom door. Check to make sure that engine latch will closetightly with SUB-ENGINE SWITCH, 1900. Tools: Extension / Ratchet / 7/16” Socket / 7/16” Wrench

  14. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 14DATE: 9/8/08 Shop Note: If necessary, adjust position ofthe WELD-ENG CATCH INNER SW/A PNTD. Swing the engine toward the center of the frame so that the indexing tabs engage the INNER and OUTER ENGINE CATCHES. If they do not engage properly, adjust the SCREWS on the underside of the ASSY-ENGINE PIVOT SUB so that the SUB-ENG tabs engage the ENGINE CATCHES properly. If necessary, adjust position of the WELD-ENG CATCH INNER SW/A PNTD. Once the INNER ENGINE CATCH is adjusted properly, tighten the SCREWS completely as shown. Swing the engine back in. Tools: 9/16” Wrench / 9/16” Socket / Air Ratchet

  15. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 15DATE: 9/8/08 Adjust position of engine latch again if necessary, then retighten. After latch is adjusted properly, apply 2 drops of (BLUE LOCTITE 242) (3401390) to the threads, one drop on either side of the ball joint as shown. 3401390 Tools: 9/16” Wrench / 9/16” Socket / Air Ratchet

  16. 3400080 MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 16DATE: 9/8/08 Get (1) WELD-CATCH ENGINE SWING (3335195), (2) SCR-HEX,5/16-18X1.00 ZP (3400035) and (2) NUTS-HEX 5/16-18 ES ZP (3400080). 3400035 3400080 Swing the SUB-ENG out. Insert (2) SCRS-HEX through top of engine pan and WELD-CATCH ENGINE SWING under edge of pan, as shown. Secure each SCR-HEX with NUT-HEX inside WELD-CATCH ENGINE SWING. Tighten. Swing the SUB-ENG in and out to make sure WELD-CATCH ENGINE SWING latches properly with 3317117 SUB-ENGINE LOCK. Readjust position of WELD-CATCH ENGINE SWING if necessary. Tighten. 3335195 3335195 3317117 SUB-ENGINE LOCK Parts: 3335195 / 3400035 / 3400080 Tools: ½” Socket / ½” Wrench / Air Ratchet

  17. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 17DATE: 9/8/08 000708 000708 Apply SILICONE-RTV 10 OZ TUBE (000708) to the slotted holes in the frame for the hardware securing the SUB-ENGINE SWITCH, 1900 as shown. Tools: Caulk Gun

  18. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 18DATE: 9/8/08 3307792 3400080 End bent beyond 90o 3307791 Place endbent beyond 90o of BAR-HOSE PAN SUPPORT under PAN-HOSE, as shown, and secure with (1) screw with flat-washer inserted from bottom and flat-washer with nut on top. Place PAN-HOSE under engine with BAR-HOSE PAN SUPPORT on frame at front and PAN-HOSE on frame at rear. At rear, insert (2) screws with flat-washers through bottom and secure with flat-washers and nuts on top. Get (1) BAR-HOSE PAN SUPPORT SW/A PNTD (3307792), (1) PAN-HOSE SW/A PNTD (3307791), (4) SCR-HEX,5/16-18X1.00 ZP (3400035), (8) WASHER-FLAT 5/16 IDx.688 ODx.0 (3400088) and (4) NUT-HEX 5/16-18 ES ZP (3400080). Parts: 3307792 / 3307791 3400035 / 3400088 3400080

  19. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 19DATE: 9/8/08 3400080 and 3400088 3307792 3400035, 3400080 & 3400088 3307791 Insert 4th screw with flat-washer under frame and through top end of BAR-HOSE PAN SUPPORT and secure on top with flat-washer and nut, as shown at left. Tighten hardware at front and rear of BAR-HOSE PAN SUPPORT and PAN-HOSE. Tools: Air Ratchet / ½ ” Socket / ½” Wrench

  20. 3400384 MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 20DATE: 9/8/08 3400384 3400034 3400036 3335134 3335394 Get (1) WELD-EXHAUST FUNNEL, ARMA (3335134) and (1) PLT-MOUNT BRKT, FUNNEL, ARMA (3335394). Place (2) WASHER-CONICAL SPRING 5/16 (3400384) onto (2) SCR-HEX,5/16-18X1.25 ZP (3400034). Secure the PLT-MOUNT BRKT to the frame using the SCREWS and WASHERS, inserted from the bottom of the frame as shown. Thread (2) NUT-FLANGE LOCK 5/16-18 (3400390) onto the SCREWS. Hand tighten. 3400390 Place (4) WASHER-CONICAL SPRING 5/16 (3400384) onto (4) SCR-HEX, 5/16-18x0.75 ZP (3400036). Secure the EXHAUST FUNNEL to the PLT-MOUNT using the SCREWS and WASHERS, inserted from the bottom of the unit as shown. Thread (4) NUT-FLANGE LOCK 5/16-18 (3400390) onto the SCREWS. Hand tighten. Adjust the EXHAUST FUNNEL to align with the exhaust pipe on the SUB-ENG. Tighten all hardware. Parts: 3335134 / 3335394 / 3400384 / 3400034 3400390 / 3400036 Tools: Air Ratchet / ½” Socket

  21. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 21DATE: 9/8/08 3335978 3301158 3400036 3400384 3400390 Route unconnected end of 3335978HOSE-LP FUEL under frame at rear of engine, on top of hose retainer on left side of engine, behind remote oil filter lines and up to LP Vaporizer. Shop Note: (2) 3301158 CLAMPS-CABLE ¾ must be oriented as shown on top of hose retainer. Get (2) CLAMP-CABLE ¾ (3301158), (1) SCR-HEX, 5/16-18x0.75 ZP (3400036), (1) WASHER-CONICAL SPRING 5/16 (3400384) and (1) NUT-FLANGE LOCK 5/16-18 (3400390). Secure 335978 HOSE-LP on top-rear of hose retainer with (1) CLAMP, screw, washer and nut. Place 2nd CLAMP around LP hose and on top-front screw behind hose retainer. Tighten hardware on (2) clamps on hose and hardware securing hose retainer. Remove top (2) screws and nuts securing hose retainer on top of hoses on left side of engine. Loosen bottom two screws. Parts: 3301558 / 3400036 / 3400384 / 3400390 Tools: 7/16” Wrench / 7/16” Socket / ½” Wrench / ½” Socket / Ratchet

  22. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 22DATE: 9/8/08 LP Vaporizer 3342097 3335978 3342097 Get (1) FTG-SAE 5/8-18 45 DEG FLARE (3342097). Apply 565 PST.ThrdSlnt50ml (WHITE LOCTITE 565) (3401122) to threads of FTG-SAE 5/8-18 45 DEG FLARE and thread into LP Vaporizer on engine. Tighten. Connect end of 3335978HOSE-LP FUEL to 3342097FTG-SAE5/8-18 45 DEG FLAREon LP Vaporizer. Tighten. Parts: 3342097 Tools: ¾” Wrench / 5/8” Wrench

  23. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 23DATE: 9/8/08 3335978 3302493 3335978 Use (3) TIE-WIRE (3301358) to secure 3335978HOSE-LP FUEL to top of other engine hoses at rear of hose retainer, as shown above. Pull ties tight and cut off excess ends. Swing engine in and out fully to check position of 3335978 HOSE-LP FUEL maintaining clearance on both sides of frame crossbar at rear of engine, as indicated above. Tools: Wire Cutters Parts: 3301358

  24. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 24DATE: 9/8/08 3335066 3335066 Get (1) SUB-HYD RESV. 1900 (3335066), (4) SCR-HEX 5/16-18X1.00 ZP (3400035), (4) WASHER-FLAT 5/16 IDx.688 ODx.0 (3400088) and (4) NUT-HEX 5/16-18 ES ZP (3400080). Slide the SUB-HYD RESV. 1900 underneath the right side of frame as shown. Lift the SUB-HYD RESV. 1900 up and align the (2) holes in the inside angle brackets on the SUB-HYD RESV. 1900 with (2) inside slots on the angles that are welded to the frame. Place a WASHER onto each SCR-HEX. Insert (2) SCR-HEX with washers through the (2) inside slots on the angles that are welded to the frame and angle brackets on the SUB-HYD RESV. 1900. Secure each SCR-HEX with a NUT-HEX. Hand tighten. Other (2) screws, washers and nuts are installed after installation of STRAP-FUEL TANK SW/A for DSL units only. 3400035 3400088 Parts: 3335066 / 3400035 / 3400088 / 3400080

  25. DSL Units Only MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 25DATE: 9/8/08 3307731 3307731 3307731 Bend the STRAP-FUEL TANK SW/A into a “U” shape. Shop Note: Make sure ends of STRAP-FUEL TANK SW/A are not hanging on the outside of the unit. Get (1) STRAP-FUEL TANK SW/A (3307731) and insert under two angle brackets on frame and above the SUB-HYD RESV. 1900 as shown. Parts: 3307731

  26. Shop Note: Before tightening all (4) screws and nuts, push SUB-HYD RESV. 1900 as far to the right of the frame as possible. MODEL: 1900 JONAS - WC04DOCUMENTED BY: John MyersPAGE NUMBER: 26DATE: 9/8/08 3400088 3400035 Lift the SUB-HYD RESV. 1900 up and align the (2) holes in the outside angle brackets on the SUB-HYD RESV. 1900 with the outside slots on the angles that are welded to the frame. Place (1) 3400088 WASHER onto each of remaining (2) 3400035 SCR-HEX 5/16. Insert (2) 3400035 SCRS-HEX 5/16 with 3400088 WASHERS through (2)outside slots on the angles that are welded to the frame and angle brackets on the SUB-HYD RESV. 1900 as shown. Secure each SCR-HEX with a 3400080 NUT-HEX under brackets on reservoir. Before tightening all (4)screws and nuts, push SUB-HYD RESV. 1900 as far to the right of the frame as possible. Tighten all (4) screws and nuts. That completes WC-04. 3400088 / 3400035 Tools: Air Ratchet / ½” Socket / ½” Wrench

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