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Assembly Instructions: 1900 JONAS WC – 01 (Station 1) Pages 1-48

Detailed step-by-step guide with images for assembling Model 1900 Jonas WC01 vehicle steering console. Includes tools, parts, and safety precautions.

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Assembly Instructions: 1900 JONAS WC – 01 (Station 1) Pages 1-48

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  1. MODEL: 1900 JONAS - WC01DOCUMENTED BY: John Myers PAGE NUMBER: 1DATE: 10/28/08 Authorized By: Assembly Instructions: 1900 JONAS WC – 01 (Station 1) Pages 1-48 P:\ISO 9001 2000\Work Instructions\Assembly\Main Assembly Line\JONAS 1900 AY25 Rev 1

  2. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 2DATE: 10/28/08 Shop Note: Reference this page for orientation of Right and Left sides of unit, driver’s perspective. Get (1) WELD - MAIN FRAME, 1900 (3335040) and position as shown. Tap the holes in the center of the WELD-9XV TILT STEERING mounting tabs of the MAIN FRAME. Right Left Parts: 3335040 Tools: Ratchet / 3/8” –16 Tap

  3. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 3DATE: 10/28/08 3334923 Steering column rubber boot not centered in hole on steering console, shown before adjustment. Get (1) ASSY-STEERING CONSOLE, 1900 (3334923). Check steering column on steering motor to make sure rubber boot is centered in hole on steering console. If column is not centered, loosen and adjust position of (4) screws securing steering motor in console to properly center rubber boot on column in hole, as shown. Then retighten screws. Steering column rubber boot properly centered in hole on steering console, shown after adjustment. Shop Note: DO NOT INSTALL 3334923 ASSY-STEERING CONSOLE, 1900 ifsteering motor is not painted black. Get sub with motor painted black as shown. Parts: 3334923 Tools: 9/16” Socket / Ratchet

  4. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 4DATE: 10/28/08 3400210 3400079 3400210 3400079 Get (2) SCR-SOC,3/8-16X1.50 ZP (3400210) and (2) NUT-HEX 3/8-16 ES ZP (3400079). Align the STEERING CONSOLE with the cut-out section near the top-right portion of the MAIN FRAME and position as shown, aligning the plastic bushings with the holes tapped previously. Insert SCRS-SOC through bushings inside ASSY-STEERING CONSOLE, 1900 and into threaded holes in frame. One person holds ASSY-STEERING CONSOLE, 1900 in place while second person inserts SCRS-SOC, as shown. Secure on outside of frame tabs with NUT-HEX 3/8-16 ES ZP. Snug tighten. 3400210 Parts: 3400210 / 3400079 Tools: 9/16” Ratchet Wrench / 3/8” Allen-Head Socket / Extension / Air Ratchet

  5. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 5DATE: 10/28/08 3307163 3400087 3400752 3400087 3400125 3400752 3300414 3300414 Get (1) WELD-LATCH TILTSTEER SW/A PLTD (3307163), (1) PIN-CLEVIS 3/8 X 2-1/4 ZP (3400752), (1) PIN-COTTER 3/8 RUE-RING (3400125) and (2) WASHER-FLAT 3/8 STANDARD ZP (3400087). Place (1) WASHER-FLAT 3/8 onto PIN-CLEVIS 3/8 X 2-1/4 ZP. Insert PIN-CLEVIS through the WELD-LATCH TILTSTEER and (2) BUSHING-PLASTIC. Place (1) WASHER-FLAT 3/8 onto PIN-CLEVIS. Secure with PIN-COTTER 3/8 RUE-RING. Insert (2) BUSHING-PLASTIC MN BRM (3300414) into the holes in the ends of the brackets on hopper side of frame, as shown. Parts: 3300414 / 3307163 / 3400752 / 3400125 / 3400087

  6. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 6DATE: 10/28/08 Insert (1) SCR-HEX,1/4-20X2.00 ZP (3400039) through the upper holes in the WELD-LATCH TILTSTEER. Place (1) SPRING-TILT STEERING SW/A (3307815) onto 3400039 SCR-HEX,1/4-20X2.00 ZP before pushing through left hole and securing with (1) NUT-HEX 1/4-20 ES ZP (3400081). Insert (1) SCR-HEX,1/4-20X2.25 ZP (3400351) through the bottom set of holes in the bracket and securing with (1) NUT-HEX 1/4-20 ES ZP (3400081). Tighten. Stretch the SPRING-TILT STEERING and hook the end onto middle of the 3400351 SCR-HEX,1/4-20X2.25 ZP as shown. 3400039 3400081 3307815 Swivel the ASSY-STEERING CONSOLE, 1900 to ensure that the pin indexes from top slot, as shown at left, to bottom slot, as shown above, of WELD-LATCH TILTSTEER SW/A PLTD. 3400351 Parts: 3400039 / 3307815 3400081 / 3400351 Tools: 7/16” Ratchet Wrench / 7/16” Socket / Extension / Air Ratchet

  7. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 7DATE: 10/28/08 3400079 On the hopper side of the MAIN FRAME, tighten the nuts that secure the 3400210 SCR-SOC,3/8-16X1.50 ZP on each side of the steering assembly, as shown. Complete installed ASSY-STEERING CONSOLE, 1900 is shown at bottom right, as seen from driver’s compartment. Tools: 9/16” Ratchet Wrench / 3/8” Allen-Head Socket / Extension / Air Ratchet

  8. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 8DATE: 10/28/08 3500117 Cut 8” of EDGING-VINYL TRIM 3/16" X 250‘ (3500117) and apply around the edge of the hole in the MAIN FRAME to the left of the ASSY-STEERING CONSOLE, 1900. Cut to fit. Parts: 3500117 Tools: Side Cutters

  9. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 9DATE: 10/28/08 3335642 Position (1) ASSY-IMPELLER, HYD (3335642) on the operator’s side of the MAIN FRAME. Insert the exhaust tube through the hole near the center of the MAIN FRAME hopper wall. Align the welded studs protruding through the isolation mounts with the mounting holes. Secure on the hopper side with (3) WASHER-FLAT 3/8 STANDARD ZP (3400087) and (3) NUTS-HEX 3/8-16 ES ZP (3400079). Do not tighten. 3308766 3400087 / 3400079 Parts: 3335642 / 3400087 / 3400079

  10. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 10DATE: 10/28/08 Before tightening the nuts, pull up on the SUB-HYD, IMPELLER so that the welded studs are at the top of the slotted holes. Tighten the nuts from the hopper side of the MAIN FRAME, as shown at right, while lifting up on the impeller, as shown above. Shop Note: Pull up on the SUB-HYD, IMPELLER while tightening hardware so that the welded studs are at the top of the slotted holes. Tools: Air Ratchet / 9/16” Socket

  11. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 11DATE: 10/28/08 3300379 3400081 3400104 / 3400081 3400080 3400088 3400273 3400035 Get (1) HORN-12V STANDARD AUTOMOTIVE (3300379). Secure the metal bracket supplied with the HORN to the HORN using (1) NUT-HEX 1/4-20 ES ZP (3400081). Tighten. Insert (1) SCREW-HEX,5/16-18X1.00 ZP (3400035) with (1) WASHER-FLAT 5/16 IDx.688 (3400088) through the engine side of the MAIN FRAME. Place (1) WASHER-STAR 5/16 ZP INT TEETH (3400273) on the SCREW-HEX on hopper side. Secure the HORN to the FRAME as shown using (1) NUT-HEX 5/16-18 ES ZP (3400080). Tighten. Parts: 3300379 / 3400081 / 3400035 / 3400088 3400273 / 3400080 Tools: 7/16” Wrench / ½” Wrench / ½” Socket / Ratchet

  12. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 12DATE: 10/28/08 3400087 3335447 3335446 3400027 3400079 Get (1) WELD-HOSE RETAINER 1900 (3335300) and place between the firewall and floor of frame, as shown. At front of HOSE RETAINER between firewall and HOSE RETAINER shim as required to fill gap with SPACER-.179 HOSE RETAINER 1900 (3335446) or SPACER-.060 HOSE RETAINER 1900 (3335447). Fasten front with (2) SCR-HEX,3/8-16X1.75 ZP (3400027) with (4) WASHER-FLAT 3/8 STANDARD ZP (3400087), (1) flat-washer on each end of screws, as shown. Secure with (2) NUT-HEX 3/8-16 ES ZP (3400079). At rear of HOSE RETAINER, fasten to bracket on floor of frame with (2) SCR-HEX,1/2-13X2.50 ZP (3400019), (4) WASHER-FLAT 1/2 STANDARD ZP (3400086), (1) flat-washer on each end of screws, as shown, and (2) NUT-HEX 1/2-13 ES ZP (3400078). 3335446 3400086 3335300 3400078 3400019 Parts: 3335300 / 3335446 / 3335447 / 3400027 / 3400087 / 3400079 / 3400019 / 3400086 / 3400078

  13. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 13DATE: 10/28/08 3335447 3335446 Shop Note: If firewall on frame begins to bend while tightening front of WELD-HOSE RETAINER 1900,add or remove SPACERS to fill the gap. Do not bend frame. Tighten front of WELD-HOSE RETAINER 1900 first, then tighten rear. Tools: ¾” Wrench / ¾” Socket / 9/16” Wrench / 9/16” Socket / Air Ratchet

  14. Insert the other end of the CYLINDER – LIFT into the center groove of the MAIN FRAME as shown. Insert (1) WELD-PIN LIFT CYL, CAP END (3335295) through the MAIN FRAME and the CYLINDER – LIFT from the left side of the machine. Tap completely through the CYLINDER-LIFT. Place (1) WASHER-FLAT 5/16 IDx.688 ODx.0 (3400088) on (1) SCR-HEX,5/16-18X1.00 ZP (3400035). Insert SCR-HEX through the WELD-PIN into the MAIN FRAME as shown. Tighten. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 14DATE: 10/28/08 3335237 Rod End Get (1) CYLINDER - LIFT, W CB VLV, 1900 (3335237) with Rod End. Attach included Rod End to the threaded end of the CYLINDER – LIFT. 3335295 3400088 3400035 Parts: 3335237 / 3335295 / 3400088 / 3400035 Tools: Hammer / Ratchet / ½” Socket

  15. Get (2) FTG-90° 3/4-16 STOR X #4 JIC3 (3401446). Thread both FTG-90° into the threaded ports on the CYLINDER - LIFT. Orient the FTG-90° so that they are pointed toward the front of the machine and are angled slightly down as shown. Tighten the jam nut on each FTG-90°. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 15DATE: 10/28/08 3401446 Parts: 3401446 Tools: (2) 15/16” Wrenches

  16. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 16DATE: 10/28/08 3400262 / 3400067 Tap Tap out hole in the mounting tab shown above. Thread (1) NUT-HEX 3/8-24 ZP (3400067) onto (1) SCREW-HEX,3/8-24X1.25 ZP F'THD (3400262). Thread SCREW-HEX into the bracket. Parts: 3400262 / 3400067 Tools: Ratchet / 9/16” Socket / 3/8-24 Tap

  17. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 17DATE: 10/28/08 3335183 34000379 3400392 3400262 / 3400067 Place (1) WELD-INNER ENG CATCH, ARMA (3335183) next to 3400262 SCREW-HEX,3/8 on top of frame, as shown. Insert (2) SCR-CAR,3/8-16X1.00 ZP (3400379) through WELD-INNER ENG CATCH and frame. Secure with (2) NUT-FLANGE LOCK 3/8-16 (3400392) under frame. Hand tighten. Parts: 3335183 / 3400379 / 3400392

  18. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 18DATE: 10/28/08 3335705 3400080 / 3400088 Get (1) SUB-ENGINE SWITCH, 1900 (3335705) andplace on left side frame behind firewall, over slotted holes, as shown above. Place (4) WASHER-FENDER 5/16 1.00 OD (3400233) on (4) SCR-HEX,5/16-18X1.00 ZP (3400035) and insert, from the bottom of the MAIN FRAME, through the SUB-ENGINE SWITCH. Secure on top with (4) WASHER-FLAT 5/16 IDx.688 ODx.065 THK (3400088) and (4) NUT-HEX 5/16-18 ES ZP (3400080). Hand tighten only. Shop Note: Install SUB-ENGINE SWITCH, 1900 without PLATE-SPACERS, ENG CATCH (3335522). Parts: 3335705 / 3400233 / 3400035 / 3400088 / 3400080

  19. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 19DATE: 10/28/08 3335657 3321296 3401452 Place (1) PAD-RUBBER, BATTERY, .25" X 11" X 7“ (3335657) inside WELD-BATTERY BOX, as shown. Position (1) WELD-BATTERY BOX (SW W/SWING) (3321296) inside front-left of the frame, in front of SUB-ENGINE SWITCH, 1900, as shown. Get (2) SCR-TRUSS HEAD 5/16 X 1.0 PH ZP (3401452) and insert through the WELD-BATTERY BOX. Secure screws through the WELD-BATTERY BOX under the frame with (2) WASHERS-FENDER 5/16 1.00 OD (3400233) and (2) NUT-HEX 5/16-18 ES ZP (3400080). Tighten. Parts: 3321296 / 3401452 / 3400233 / 3400080 / 3335657 Tools: ½” Wrench / ½” Socket / Ratchet / Phillips Screwdriver

  20. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 20DATE: 10/28/08 Get (1) FUSE-BOX JONAS (HOLDS 2 STRIP FUSES) (90184664), (2) SCR-PAN,#10-24X0.75,PHL (3400268), (2) WASHER-FLAT #10 ZP (3400095) and (2) NUT-HEX NYLON LOCK #10-24 SS (3400399). 90184664 3400268 3400095 / 3400399 Place FUSE-BOX JONAS on rear bracket of WELD-BATTERY BOX, oriented as shown with cover opening toward battery and closing away from battery. Insert (2) SCR-PAN,#10-24X0.75,PHL through FUSE-BOX JONAS tabs and WELD-BATTERY BOX. Secure with (2) WASHER-FLAT #10 ZP and (2) NUT-HEX NYLON LOCK #10-24 SS under bracket on WELD-BATTERY BOX. Tighten. Parts: 90184664 / 3400268 / 3400095 / 3400399 Tools: Phillips Screwdriver / 3/8” Wrench

  21. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 21DATE: 10/28/08 3400042 / 3400383 Shop Note: Apply 3-36 Spray Lubricant (3401468) before inserting the Rubber Bumpers into holes. 3300526 3300526 Get (2) BUMPER-RUBBER 1/4 ID X 1/8 THK (3300526) and (2) PLT-STOP, SIDE DOOR, ARMA (3335015). Apply 11oz3-36MltPrpsLb (3401468) to each BUMPER-RUBBER. Insert a BUMPER-RUBBER into each PLT-STOP as shown. Attach the top PLT-STOP to the left side of the MAIN FRAME using (2) SCR-HEX,1/4-20X0.75 ZP (3400042) and (2) WASHER-CONICAL SPRING ¼ (3400383) inserted through the engine side of the MAIN FRAME. Secure with (2) NUT-FLANGE LOCK 1/4-20 ZP (3400063). Do not tighten. 3335015 Parts: 3300526 / 3335015 / 3400042 / 3400383 / 3400063

  22. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 22DATE: 10/28/08 3335015 3400042 / 3400383 Parts: 3335174 / 3400042 / 3400383 / 3400063 3400042 / 3400383 3400042 / 3400383 3335174 3335015 3400042 / 3400383 3335174 Attach the bottom PLT-STOP to the bottom left of the MAIN FRAME with (1) SCR-HEX,1/4-20X0.75 ZP (3400042) and (1) WASHER-CONICAL SPRING ¼ (3400383) inserted through the engine side. Secure with (1) NUT-FLANGE LOCK 1/4-20 ZP (3400063). Do not tighten. Attach (1) WELD - SIDE DOOR STRIKE ARMA (3335174) in between the upper and lower PLT-STOPS with (2) SCREWS-HEX,1/4-20X0.75 ZP (3400042) and (2) WASHER-CONICAL SPRING ¼ (3400383) inserted through the engine side. Secure with (2) NUT-FLANGE LOCK 1/4-20 ZP (3400063). Do not tighten. 3335015 3400042 / 3400383

  23. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 23DATE: 10/28/08 Switch Cap Get (1) SWITCH-IGNITION, 3-POS, W/STARTER LOCKOUT (3316100). Remove the metal cap and keys from the front of the SWITCH. Insert the SWITCH through the MAIN-FRAME next to the WELD-9XV TILT STEERING. Thread the cap back onto the SWITCH. Tighten. Insert the keys back into the SWITCH. 3316100 Parts: 3316100

  24. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 24DATE: 10/28/08 Get (1) GAUGE-4 IN 1, 3.5" DIA W/TWO 6 (3335487). Insert the GAUGE through the MAIN-FRAME next to the WELD-9XV TILT STEERING as shown. Orient the GAUGE as shown. Turn the metal ring in the cap AND POSITION IT IN CENTER OF THE THREADS. Twist the cap onto the GAUGE until snug. Adjust the GAUGE if necessary to orient as shown above right after tightening. 3335487 Metal Ring Cap Parts: 3335487

  25. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 25DATE: 10/28/08 3323529 3336028 3323529 Insert (1) 3323529 PLUG-CARLING CONTURA SWITCH into the rear slot on right side of the ASSY-STEERING CONSOLE, as shown above. Get (2) PLUG-CARLING SWITCH W/ CONN ATTACH'M (3336028) and (3) PLUG-CARLING CONTURA SWITCH (3323529). Insert (2) 3336028 PLUG-CARLING SWITCH W/ CONN ATTACH'M into the lower (2) switch holes in the lintel on the left, as shown. Insert (2) 3323529 PLUG-CARLING CONTURA SWITCH into the lower (2) switch holes in the lintel on the right, as shown Shop Note: 3323529 PLUG-CARLING CONTURA SWITCH should be pre-installed in sub 3334923 ASSY-STEERING CONSOLE, 1900. If sub ASSY-STEERING CONSOLE, 1900 is not pre-built, install PLUG as shown. Parts: 3336028 / 3323529

  26. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 26DATE: 10/28/08 3336033 LP Units Only DSL Units Only Get (1) DECAL-ELECTRICAL SCHEMATIC LABELS (3336033). For DSL Units Only: Under lintel apply decals at top and bottom of top row of switch holes, as shown. From left, driver’s perspective, H2 at top, H1 at bottom; H4 at top, H3 at bottom; H6 at top, H5 at bottom; H7 at top, H8 at bottom. For LP Units Only: Under lintel apply decals at top and bottom of top row of switch holes, as shown. From left, driver’s perspective, H12 at top, no decal at bottom; H4 at top, H3 at bottom; H6 at top, H5 at bottom; H7 at top, H8 at bottom. Parts: 3336033

  27. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 27DATE: 10/28/08 LP Units Only DSL Units Only 3336027 19256106 19255694 19255595 19255678 19255694 19256106 19255595 For LP Units Only: Insert switch lights in top row of holes as shown, from left: (1) LIGHT-INDICATOR CHECK ENGINE CARLING (3336027), (1) LIGHT-INDICATOR CLOGGED FILTER/IMPELLER OFF (19256106), (1) LIGHT-INDICATOR TURN SIGNAL/RTR (19255694) and (1) LIGHT-INDICATOR PARK BRAKE (19255595). For DSL Units Only: Insert switch lights in top row of holes as shown, from left: (1) LIGHT-INDICATOR BATTERY/GLOW PLUG (19255678), (1) LIGHT-INDICATOR CLOGGED FILTER/IMPELLER OFF (19256106), (1) LIGHT-INDICATOR TURN SIGNAL/RTR (19255694) and (1) LIGHT-INDICATOR PARK BRAKE (19255595). Parts: 19255678 or 3336027 / 19256106 / 19255694 / 19255595

  28. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 28DATE: 10/28/08 Caulk the open slots on left side of the WELD-BATTERY BOX and at rear of SUB-ENGINE SWITCH as shown with SEALANT-CLEAR SILICONE RUBBER (3301652). Apply SEALANT-CLEAR SILICONE RUBBER to the gaps along both edges on the left and right sides of the MAIN FRAME where shown. Tools: Caulking Gun

  29. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 29DATE: 10/28/08 3400035 / 3400384 Secure the Safety Leg Brace to the front-center of the MAIN FRAME under the lintel as shown using (2) SCR-HEX,5/16-18X1.00 ZP (3400035) and (2) WASHER-CONICAL SPRING 5/16 (3400384). Tighten. Tools: Safety Leg Brace / ½” Socket / Ratchet

  30. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 30DATE: 10/28/08 Hoist the rear of the MAIN FRAME up and leave suspended as shown. Tools: 1-Ton Hoist / Strap

  31. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 31DATE: 10/28/08 3343740 3400029 / 3400087 3400087 / 3400079 Secure (1) TIE DOWN-UNIVERSAL, REAR (3343740) under the bottom rear of the MAIN FRAME as shown with (2) SCR-HEX, 3/8-16x1.25 ZP (3400029), (4) WASHER-FLAT 3/8 STANDARD ZP (3400087) and (2) NUT-HEX 3/8-16 ES ZP (3400079). Place (1) WASHER-FLAT on each screw and insert through TIE DOWN-UNIVERSAL, REAR and bottom of frame. Secure inside frame with (1) WASHER-FLAT and NUT-HEX on each screw. Tighten. 3400029 / 3400087 Parts: 3343740 / 3400029 / 3400087 / 3400079 Tools: 9/16” Socket / Air Ratchet / 9/16” Wrench

  32. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 32DATE: 10/28/08 Cut ~ 44” of EDGING-VINYL TRIM 3/16" X 250' (3500117). Press the channel of the edging around the left-rear edge of the MAIN FRAME and cut to fit as shown. Save unused portion of trim. 3500117 Parts: 3500117 Tools: Side Cutters

  33. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 33DATE: 10/28/08 Shop Note: Ensure the Safety Leg is secure. 3500117 3500116 Press the remainder of the EDGING-VINYL TRIM 3/16“ X 250' along the lower left edge of the FRAME and cut to fit, as shown above. Cut ~ 18” of EDGING-VINYL 5/16 (3500116). Press the channel of the edging on the top edge of the L-Bracket and cut to fit as shown above. Hoist the unit to rest on the ‘nose’ and the Safety Leg, as shown. Ensure the Safety Leg is secure. Parts: 3500116 Tools: Side Cutters / Hoist / Strap

  34. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 34DATE: 10/28/08 Cut ~ 8” of EDGING-VINYL TRIM 3/16" X 250‘ (3500117). Press the channel of the edging on the edge of the cut out shown on the right side of the MAIN FRAME and cut to fit. 3500117 Parts: 3500117 Tools: Side Cutters

  35. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 35DATE: 10/28/08 3335281 Elastic Nuts Slot Grease Fitting 3335281 Get (1) SUB-ENGINE PIVOT, ARMA (3335281). Remove and save (4) elastic nuts. Orient the grease fitting on the SUB-ENGINE PIVOT, ARMA so that it slides through the slot shown above. Insert the SUB-ENGINE PIVOT through the hole. Parts: 3335281

  36. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 36DATE: 10/28/08 3335281 Mount the SUB-ENGINE PIVOT as shown . Secure the SUB-ENGINE PIVOT with the previously removed elastic nuts. Tighten. Tools: Ratchet / 9/16” Socket / 9/16” Wrench

  37. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 37DATE: 10/28/08 Position (1) SUB-ENGINE LOCK (3317117) on the left side of the MAIN FRAME near the SUB-ENGINE SWITCH. Secure with (2) SCR-CAR,5/16-18X1.00 ZP (3400009) and (2) NUT-FLANGE LOCK 5/16-18 (3400390) in the rear slotted holes. Push SUB-ENGINE LOCK up in slotted holes while tightening nuts. 3317117 3400009 Push SUB-ENGINE LOCK 3317117 Parts: 3317117 / 3400009 / 3400390 Tools: Phillips Screwdriver / Air Ratchet / ½” Socket

  38. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 38DATE: 10/28/08 3400035 / 3400088 / 3400080 3307220 Insert (1) BEARING-DIR CONTROL SW/A (3307220) into the hole in (1) MNT-BUSHING DIR CONT SW/A bracket (3307223) with the flange oriented as shown. 3307220 3400035 / 3400088 / 3400080 3307223 3307223 Install the MNT-BUSHING DIR CONT SW/A to the top surface of the MAIN FRAME on right side as shown with (2) SCREWS-HEX 5/16-18X1.00 ZP (3400035), (4) WASHER-FLAT 5/16 IDx.688 OD (3400088) and (2) NUTS-HEX 5/16-18 ES ZP (3400080). Insert screws with flat-washers through bottom of frame. Secure on top of MNT-BUSHING with flat-washers and nuts. Tighten. 3400035 / 3400088 Parts: 3307220 / 3307223 / 3400035 / 3400088 / 3400080 Tools: Ratchet / ½” Socket / ½” Wrench

  39. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 39DATE: 10/28/08 3307215 Shop Note: The end with the longer connecting link inserts into this MNT-BUSHING DIR CONT SW/A. Get (1) WELD-DIR TORQUE TUBE SW/A PNTD (3307215). Remove tape from ends and spray 11oz3-36MltPrpsLb (3401468) on end with longer connecting link, as shown above. Insert end of WELD-DIR TORQUE TUBE SW/A PNTD with longer connecting link into MNT-BUSHING DIR CONT SW/A on right side, as shown above. Parts: 3307215

  40. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 40DATE: 10/28/08 3307220 3307223 Insert (1) BEARING-DIR CONTROL SW/A (3307220) into (1) MNT-BUSHING DIR CONT SW/A (3307223) as shown at left. Insert other end of WELD-DIR TORQUE TUBE SW/A PNTD with shorter connecting link into MNT-BUSHING DIR CONT SW/A on left side of frame, as shown above. Parts: 3307220 / 3307223

  41. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 41DATE: 10/28/08 3400035 / 3400278 3400035 / 3400088 / 3400080 Install MNT-BUSHING DIR CONT SW/A on the left side of the frame with (2) SCREWS-HEX,5/16-18X1.00 ZP (3400035) and (2) WASHERS-FENDER 3/8 (3400278) inserted through the bottom of the MAIN FRAME, as shown at left. Secure top of MNT-BUSHING DIR CONT SW/A with (2) WASHER-FLAT 5/16 IDx.688 OD (3400088) and (2) NUTS-HEX 5/16-18 ES ZP (3400080), as shown above. Snug tighten. Parts: 3400035 / 3400278 / 3400088 / 3400080 Tools: Ratchet / ½” Socket / ½” Wrench

  42. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 42DATE: 10/28/08 1/8” plate Push WELD-DIR Push the WELD-DIR TORQUE TUBE towards the right side (driver’s perspective) of the machine. Insert 1/8” plate between the WELD-DIR TORQUE TUBE bracket and MNT-BUSHING DIR on the right side, as shown at top right. Tighten the NUTS-HEX on the MNT-BUSHING DIR on the left side, as shown at bottom right. Ensure that the plate stays securely wedged while tightening. Remove the plate. Twist WELD-DIR TORQUE TBUE to ensure that it is able to pivot freely. Tools: Ratchet / ½” Socket / ½” Wrench / 1/8” Plate

  43. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 43DATE: 10/28/08 3400075 3300461 3400075 3307222 3400075 3300461 Thread (2) NUT-HEX JAM 3/8-24 ZP (3400075), one onto each end of (1) ROD-DIR CONTROL DSL SW (3307222). Remove the protective covering on the threads of (2) BALL JOINTS-3/8-24 W/DUST COV (3300461). Thread (1) BALL JOINT on each end of the ROD-DIR CONTROL. Do not tighten NUTS-HEX JAM. Parts: 3400075 / 3300461 / 3307222

  44. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 44DATE: 10/28/08 3400342 Insert the threaded end of the Ball Joint on one end of ROD-DIR CONTROL into the long link on the right end of the WELD-DIR TORQUE TUBE SW/A PNTD. Secure with (1) NUT-HEX 3/8-24 ES ZP (3400342). Adjust jam nuts on each end of ROD-DIR CONTROL so ball joints are oriented as shown. Tighten. 3307222 Parts: 3400342 Tools: Ratchet / 9/16” Socket / ½” Wrench

  45. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 45DATE: 10/28/08 3400342 3307611 3335278 3400075 3335278 3307613 Thread (1) NUT-HEX JAM 3/8-24 ZP (3400075) onto the short side of the ROD-CONTROL, FWD/REV. Slide (1) BAR 2-FWD/REV QUICK RELSE PLTD (3307613) onto (1) WELD-QUICK RELEASE FWD/REV PNT {w/ BALL JOINT-3/8-24 W/QK REL}(3307611). Insert the tab of the WELD-QUICK RELEASE into the slot in the BAR. Now thread the WELD-QUICK RELEASE FWD/REV PNT {w/ BALL JOINT-3/8-24 W/QK REL} onto the ROD-CONTROL, FWD/REV. Do not tighten 3400075NUT-HEX JAM. Thread (1) NUT-HEX 3/8-24 ES ZP (3400342) onto end of BALL JOINT-3/8-24 W/QK REL. Do not tighten 3400342NUT-HEX 3/8-24 ES ZP. 3400075 3300461 Thread (1) NUT-HEX JAM 3/8-24 ZP (3400075) and (1) BALL JOINT-3/8-24 W/DUST COV (3300461) onto the long side of (1) ROD-CONTROL, FWD/REV, ARMA (3335278). Do not tighten 3400075NUT-HEX JAM. Parts: 3307613 / 3400075 / 3300461 / 3307611 / 3335278 / 3400342

  46. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 46DATE: 10/28/08 3400342 Insert the threaded portion of the BALL JOINT-3/8-24 W/DUST COV on end of ROD-CONTROL, FWD/REV, ARMA into the hole on the left end of WELD-DIR TORQUE TUBE, as shown. Secure the ROD-CONTROL, FWD/REV, ARMA with (1) NUT-HEX 3/8-24 ES ZP (3400342).Adjust jam nut on ball joint at top to orient ROD-CONTROL, FWD/REV, ARMA with crook down, as shown at right. Tighten. 3335278 Tools: Ratchet / 9/16” Socket / 9/16” Wrench Parts: 3400342

  47. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 47DATE: 10/28/08 After final assembly in WC01, sign the assembly sign-off log sheet and place behind the SUB-HYD, IMPELLER, ARMA as shown. Sign the inspection tag and tie it to the ignition keys. Assembly sign off log Inspection tag Tools: Pen

  48. MODEL: 1900 JONAS - WC01 DOCUMENTED BY: John MyersPAGE NUMBER: 48DATE: 10/28/08 Hoist the MAIN FRAME and move to WC02. Tools: Hoist / Strap

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