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AY25 Rev 1

MODEL: 1900 JONAS - WC05 DOCUMENTED BY: John Myers PAGE NUMBER: 1 DATE: 9/8/08 Authorized By:. Assembly Instructions: 1900 JONAS WC – 05 (Station 5) Pages 1-51. P:ISO 9001 2000Work InstructionsAssemblyMain Assembly LineJONAS 1900. AY25 Rev 1.

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AY25 Rev 1

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  1. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John Myers PAGE NUMBER: 1DATE: 9/8/08 Authorized By: Assembly Instructions: 1900 JONAS WC – 05 (Station 5) Pages 1-51 P:\ISO 9001 2000\Work Instructions\Assembly\Main Assembly Line\JONAS 1900 AY25 Rev 1

  2. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 2DATE: 9/8/08 Shop Note: Repeat procedure on both ends of hopper lift arm. 3400012 3335168 3400012 3400012 3307605 Get (4) FTGS-GREASE 3/16 (3400012) and tap (2) into each ASSY-DUMP ARM MOUNT SW/A PNTD, top and bottom, as shown. Inject GREASE-RONEX MULTI PURPOSE (3301841) into the (4) FTGS-GREASE to lubricate the (2) ASSY-DUMP ARM MOUNT SW/A PNTD. 3307605 Attach hoist straps to each end of (1) WELD-HOPPER LIFT ARM SW/A PNTD(3335168) and lower to floor. Get (2) ASSY-DUMP ARM MOUNT SW/A PNTD (3307605) and slide (1) onto each end of WELD-HOPPER LIFT ARMas shown. Tools: Hoist / Straps / Mallet / Punch / Grease Gun Parts: 3307605 / 3335168 / 3400012

  3. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 3DATE: 9/8/08 3400177 3400177 3400076 3300879 Place (2) BRG-THRUST 2.06 ID X 3.25 OD (3400177), 1 each, onto the pins on each end of the lift arms. Place (2) WASHER-HD 3.25 OD X 1.00 ID (3300879), 1 each, onto the pins. Thread (2) NUT-HEX JAM SLOTTED 1-14 ZP (3400076), 1 each, onto each end of the HOPPER LIFT ARMS. 3300879 Parts: 3400177 / 3300879 / 3400076

  4. Shop Note: Rotate flat side of each ASSY-DUMP ARM MOUNT toward firewall while moving WELD-HOPPER LIFT ARM into position for installation. The flat sides of the DUMP ARM MOUNTS fit against the firewall on frame on the front of the unit. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 4DATE: 9/8/08 Flat side Hoist up the HOPPER LIFT ARM and move into position for installation in front of unit. Rotate the flat side of each ASSY-DUMP ARM MOUNT SW/A PNTD toward firewall while moving WELD-HOPPER LIFT ARM SW/A PNTD into position for installation. The flat sides of the DUMP ARM MOUNTS fit against the firewall on the front of the unit. Attach hoist straps to pins on end of each hopper lift arm, one strap on each side, and attach third strap to the fork in the center. Tools: Hoist / Straps

  5. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 5DATE: 9/8/08 3400864 3400099 3400099 3400864 Align the holes in the DUMP ARM MOUNTS with the threaded holes in the brackets welded to the FRAME, as shown. Once the DUMP ARM MOUNTS are in position, place (8) WASHERS-LOCK 7/16 SPLIT ZP (3400099) on (8) SCREW-HHCS 7/16-14 X 1-1/2 (3400864). Insert (4) SCREWS with WASHERS-LOCK through holes in each DUMP ARM MOUNT and into brackets on FRAME. Parts: 3400099 / 3400864 Tools: Hoist / Straps

  6. Shop Note: Raise LIFT ARM for access to tighten bottom SCREWS. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 6DATE: 9/8/08 Tighten the SCREWS on the top of the DUMP ARM MOUNTS. Lift the WELD-HOPPER LIFT ARM for access to bottom screws. Tighten the SCREWS on the bottom of the DUMP ARM MOUNTS. Tools: Air Ratchet / 5/8” Socket / Hoist / Straps

  7. 3401390 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 7DATE: 9/8/08 (2) 3400087 3400030 3335285 (2) 3400087 3400030 Rotate end of MAIN LIFT CYLINDER out to line up with hole in end of center fork on the WELD-HOPPER LIFT ARM. Insert (1) WELD-PIN, LIFT CYL, ROD END (3335285) through the LIFT ARM and into LIFT CYLINDER. Apply drop of ND 121200-50 50 ML (BLUE LOCTITE 242) (3401390) to threads of (1) SCR-HEX,3/8-16X1.00 ZP (3400030) with (2) WASHER-FLAT 3/8 STANDARD ZP (3400087). Insert SCR-HEX with (2) WASHER-FLAT through slot in end of WELD-PIN, LIFT CYL, ROD END and into LIFT CYLINDER. Tighten. Parts: 3335285 / 3400087 / 3400030 Tools: 9/16” Socket / Ratchet / Hoist / Straps

  8. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 8DATE: 9/8/08 3335505 3335504 3335188 Safety pin Place safety pin under left side of LIFT ARM at notch as shown and lower lift arms. Disconnect straps and hoist from lift arms. Get (1) SUB-LH SECONDARY ARM JONAS 1900 (3335505), (1) SUB-RH SECONDARY ARM JONAS 1900 (3335504)and (2) WELD-PIN UPPER LIFT ARM (3335188). Use router to clear out paint from holes on each end of both SECONDARY ARMS. Insert WELD-PINthrough upper ends of both SECONDARY ARMS to test fit after routing out holes. Parts: 3335505 / 3335504 / 3335188 Tools: Hoist / Straps / Router

  9. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 9DATE: 9/8/08 3335188 3335505 Place 3335505 SUB-LH SECONDARY ARM JONAS 1900 on the left side as shown. Insert 3335188 WELD-PIN UPPER LIFT ARM through frame and rear of LH SECONDARY ARM. Tap through. Tools: Mallet

  10. 3400041 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 10DATE: 9/8/08 3400089 3400081 3400041 / 3400089 Place (1) WASHER-FLAT 1/4 STANDARD ZP (3400089) onto (1) SCR-HEX,1/4-20X0.88 ZP (3400041). Insert the SCREW through slot in the end of the WELD-PIN and the FRAME. Secure the SCREW with (1) NUT-HEX 1/4-20 ES ZP (3400081) on other side of frame. Tighten. Lower secondary arm to rest on top of lift arm. Parts: 3400089 / 3400041 / 3400081 Tools: 7/16” Socket / Ratchet / 7/16” Wrench

  11. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 11DATE: 9/8/08 3335188 3335504 3400081 3400041 / 3400089 Place 3335504 SUB-RH SECONDARY ARM JONAS 1900 on the right side as shown. Insert 3335188 WELD-PIN UPPER LIFT ARM through frame and rear of RH SECONDARY ARM. Tap through. Place (1) WASHER-FLAT 1/4 STANDARD ZP (3400089) onto (1) SCR-HEX,1/4-20X0.88 ZP (3400041). Insert SCREW with washer through slot in the end of PIN and FRAME. Secure SCREW with (1) NUT-HEX 1/4-20 ES ZP (3400081) on other side of frame. Tighten. Parts: 3400089 / 3400041 / 3400081 Tools: Mallet / 7/16” Socket / Ratchet/ 7/16” Wrench

  12. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 12DATE: 9/8/08 3400177 3300879 3400076 3400177 Remove 3400177 BRG-THRUST 2.06 ID X 3.25 OD, 3300879 WASHER-HD 3.25 OD X 1.00 ID and 3400076 NUT-HEX JAM SLOTTED 1-14 ZP from the hubs on the end of both HOPPER LIFT ARMS. Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) around outside of hubs and on threads on ends of hubs on the end of both HOPPER LIFT ARMS. Replace 3400177 BRG-THRUST 2.06 ID X 3.25 OD inside both hubs after applying grease. Shop Note: Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) to all unpainted surfaces on all parts of hopper lift arms. Tools: Latex Glove or Grease Brush

  13. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 13DATE: 9/8/08 3307074 3307074 3400177 3400177 Get (1) SUB-RH HYD CYL MNT 8X/9X/10X (3307074). Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) to hub of mount. Place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) onto hub on the SUB-RH HYD CYL MNT and tap through end of RH Secondary lift arm and end of RH Main Lift Arm, as shown. Shop Note: Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) to all unpainted surfaces on all parts of hopper lift arms. Parts: 3400177 / 3307074 Tools: Mallet / Brush

  14. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 14DATE: 9/8/08 3301709 3400177 3300882 Place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) and (1) WASHER-HD 3.25 OD X 2.00 ID (3300882) onto the pin on the ASSY-RH CYL MNT SUB on outside of RH Secondary Lift Arm, as shown. Secure with (1) RING-RET EXT 2.00 (3301709). Parts: 3301709 / 3300882 / 3400177 Tools: Snap-Ring Pliers

  15. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 15DATE: 9/8/08 3400177 / 3300879 3400076 3400122 Place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) onto the threaded pin inside main lift arm. Replace 3300879 WASHER-HD 3.25 OD X 1.00 ID and 3400076 NUT-HEX JAM SLOTTED removed earlier onto pin on lower lift arm. Tighten the NUT, aligning the slots in the castle nut with the hole in the threaded pin. Secure with (1) PIN-COTTER 1/8 X 2.00 ZP (3400122). Bend ends of pin flat on NUT-HEX JAM SLOTTED, as shown. Parts: 3400177 3400122 Tools: Channel-Locks

  16. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 16DATE: 9/8/08 3317364 3400177 Insert pin of PIVOT-HOPPER RH ARMA into end of ASSY-RH CYL MNT SUB as shown and tap through. Shop Note: Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) to all unpainted surfaces on all parts of hopper lift arms. Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) to pin of (1) PIVOT-HOPPER RH ARMA (3317364) and place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) on pin. Parts: 3317364 / 3400177 Tools: Grease Brush / Mallet

  17. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 17DATE: 9/8/08 3400177 3301709 3300882 Place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) and (1) WASHER-HD 3.25 OD X 2.00 ID (3300882) onto the pin on the PIVOT-HOPPER RH ARMA as shown. Secure with (1) RING-RET EXT 2.00 (3301709). Parts: 3301709 / 3300882 / 3400177 Tools: Snap-Ring Pliers

  18. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 18DATE: 9/8/08 3335291 3307323 Place (1) CYLINDER-ROTATION SW/A PNTD (3307323) on to top of the RH CYL MNT, aligning hole in top of cylinder with hole in top of RH CYL MNT. Insert (1) PIN REAR-ROTATION CYL PLTD (3335291) through the cylinder housing and the top hole on the RH CYL MNT. Tap through. Parts: 3307323 / 3335291 Tools: Mallet

  19. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 19DATE: 9/8/08 Right Side 3400306 3317119 3400449 Place (1) NUT-HEX JAM 1/2-20 ZP (3400449) onto (1) SCR-HEX,1/2-20X1.00 ZP (3400306). Thread the NUT all the way to the head of the SCR. Thread the SCR into (1) SUB-BLOCK ROTATION RH, 8/9/10X (3317119). Tighten. Place SUB-BLOCK ROTATION RH, 8/9/10X in vise. Tap threads in the hole in the end of the SUB-BLOCK ROTATION RH, 8/9/10X, as shown at bottom right. 1-1/4” tap Parts: 3400449 / 3400306 / 3317119 Tools: ¾” Wrench / 11/16” Wrench / 1-1/4” Tap / Vise

  20. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 20DATE: 9/8/08 3317119 3335288 With utility knife, cut plastic covering and remove from the end of the RH Lift Cylinder. Thread the ASSY-BLOCK ROTATION SUB 8/9/10 on to the end of the CYLINDER. Turn until the ASSY-BLOCK is tightened with the bolt facing down. Lower cylinder to align block with end of lift cylinder. Secure with (1) WELD-PIN ROTATE CYL, ROD END (3335288). Tap through. Parts: 3335288 Tools: Utility Knife / Mallet

  21. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 21DATE: 9/8/08 3301998 Secure PIN on inside top of RH CYLINDER-ROTATION SW/A PNTD with(1) RING-RETAINING, EXT .940 DIA (3301998). Parts: 3301998 Tools: Snap-Ring Pliers

  22. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 22DATE: 9/8/08 3335269 3335269 3400152 3335268 3335268 Replace the plugs with (2) FTG-90 1/2-20 TO #5 (3400152), oriented so the FTGS face toward the front of the unit. Attach 3335269 HOSE-HYD from RH SECONDARY LIFT ARM, to the top FTG on the CYLINDER. Attach 3335268 HOSE-HYD from RH SECONDARY LIFT ARM, to the bottom FTG on the CYLINDER. Remove plastic plugs from top of CYLINDER. Parts: 3400152 Tools: Screwdriver

  23. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 23DATE: 9/8/08 Tighten and mark both HOSES with fittings oriented down, as shown, and torque to 12 ft./lbs. Tools: 9/16” Wrench / 9/16” Torque Wrench / Red Paint Marker

  24. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 24DATE: 9/8/08 3335363 3400177 Get (1) ASSY-LH CYL MNT SUB, 1900 (3335363). Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) to hub of mount. Place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) onto hub on ASSY-LH CYL MNT SUB, 1900. Place ASSY-LH CYL MNT SUB, 1900 on to the left hand HOPPER LIFT ARM with the lift arm threaded pin in the bottom hole as shown. Next place the pin of the LH CYL MNT SUB into the hole in the LH SECONDARY LIFT ARM. Tap through. Shop Note: Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) to all unpainted surfaces on all parts of hopper lift arms. Parts: 3335363 / 3400177 Tools: Rubber Mallet / Grease Brush

  25. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 25DATE: 9/8/08 3301709 3400177 3300882 Secure with (1) RING-RET EXT 2.00 (3301709). Place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) and (1) WASHER-HD 3.25 OD X 2.00 ID (3300882) onto pin on the ASSY-LH CYL MNT SUB, 1900 as shown. Parts: 3400177 / 3300882 / 3301709 Tools: Snap-Ring Pliers

  26. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 26DATE: 9/8/08 3400177 / 3300879 3400076 Place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) onto the threaded pin inside main lift arm. Replace 3300879 WASHER-HD 3.25 OD X 1.00 ID and 3400076 NUT-HEX JAM SLOTTED removed earlier onto pin on lower lift arm. Tighten the NUT, aligning the slots in the castle nut with the hole in the threaded pin. Secure with (1) PIN-COTTER 1/8 X 2.00 ZP (3400122). Bend ends of pin flat on NUT-HEX JAM SLOTTED, as shown. 3400122 Parts: 3400177 / 3400122 Tools: Channel-Locks

  27. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 27DATE: 9/8/08 Shop Note: Pin on PIVOT-HOPPER LH ARMA (3335361) has two threaded holes, as shown on next page. 3335361 3400177 Get (1) PIVOT-HOPPER LH ARMA (3335361). Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) to pivot pin. Place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) on the pin of PIVOT-HOPPER LH ARMA. Insert pin through the hole in LH CYL MNT. Tap through. Shop Note: Apply coating of GREASE-RONEX MULTI PURPOSE (3301841) to all unpainted surfaces on all parts of hopper lift arms. Parts: 3335361 / 3400177 Tools: Grease Brush / Rubber Mallet

  28. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 28DATE: 9/8/08 3301709 3400177 3300882 Shop Note: Pin on PIVOT-HOPPER LH ARMA (3335361) has two threaded holes, as shown. Place (1) BRG-THRUST 2.06 ID X 3.25 OD (3400177) and (1) WASHER-HD 3.25 OD X 2.00 ID (3300882) onto the pin of PIVOT-HOPPER LH, as shown. Secure with (1) RING-RET EXT 2.00 (3301709). Parts: 3301709 / 3300882 / 3301709 Tools: Snap-Ring Pliers

  29. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 29DATE: 9/8/08 Left Side 3400306 3317124 3400449 Place (1) NUT-HEX JAM 1/2-20 ZP (3400449) onto (1) SCR-HEX,1/2-20X1.00 ZP (3400306) as shown above. Thread the NUT all the way to the head of the SCR. Thread the SCR into (1) SUB-BLOCK ROTATION LH (3317124). Tighten. Place SUB-BLOCK ROTATION LH in vise. Tap threads in the hole in the top of SUB-BLOCK ROTATION. 1-1/4” tap Parts: 3400449 / 3400306 / 3317119 Tools: ¾” Wrench / 11/16” Wrench / 1-1/4” Tap

  30. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 30DATE: 9/8/08 3335291 3307323 3317124 Place (1) CYLINDER-ROTATION SW/A PNTD (3307323) on to the LH CYL MNT. Insert (1) PIN REAR-ROTATION CYL PLTD (3335291) through top end of the cylinder housing and the top hole on the LH CYL MNT. Tap through. Cut paper and remove from threads on lower end of lift cylinder. Thread on SUB-BLOCK ROTATION LH to lower end of lift cylinder. Parts: 3307323 / 3335291 Tools: Mallet / Utility Knife

  31. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 31DATE: 9/8/08 3335288 Turn SUB-BLOCK ROTATION LH on end of lift cylinder to tighten until bolt is facing down, as shown. Place SUB-BLOCK ROTATION LH into top of pivot. Secure with (1) WELD-PIN ROTATE CYL, ROD END (3335288). Tap through. Parts: 3335288 Tools: Screwdriver / Mallet

  32. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 32DATE: 9/8/08 3400152 Replace the plugs with (2) FTG-90 1/2-20 TO #5 (3400152), oriented so the FTGS face toward the front of the unit. Remove plastic plugs from top of CYLINDER. Parts: 3400152 Tools: Screwdriver

  33. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 33DATE: 9/8/08 3335267 3335267 3335266 3335266 Attach 3335267 HOSE-HYD from the SECONDARY LIFT ARM, to the top FTG on the left CYLINDER. Attach 3335266 HOSE-HYD from the SECONDARY LIFT ARM, to the bottom FTG on the left CYLINDER. Tighten and mark both HOSES and torque to 12 ft./lbs. Tools: 9/16” Wrench / 9/16” Torque Wrench / Red Paint Marker

  34. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 34DATE: 9/8/08 3301998 Secure PIN REAR-ROTATION CYL PLTD at the top of LH CYL MNT with(1) RING-RETAINING, EXT .940 DIA (3301998). Parts: 3301998 Tools: Snap-Ring Pliers

  35. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 35DATE: 9/8/08 3335926 3400033 3335545 Get (2) PLATE COVER-CLAMP, TWIN SERIES (3335926), (4) CLAMP BODY-HOSE, HYD, TWINN SERIES (3335545) and (2) SCR-HEX,5/16-18X1.50 ZP (3400033). Place (1) CLAMP BODY-HOSE on each side of (2) hoses on RH Secondary Arm with (1) PLATE COVER-CLAMP on top, secured by SCR-HEX,5/16 threaded into hole in pivot pin, as shown. Tighten. Use (2) TIE-WIRE (3301358) around hoses to secure together and to bottom fitting on lift cylinder, as shown. Pull ties tight and cut off ends. Pull slack from hoses up into RH Secondary Arm. 3335545 3301358 3400033 3335926 Tools: ½” Socket / Ratchet / Wire Cutters Parts: 3335926 / 3335545 / 3400033 / 3301358

  36. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 36DATE: 9/8/08 3301358 3335545 3335926 3400033 Place (1) CLAMP BODY-HOSE on each side of (2) hoses on LH Secondary Arm with (1) PLATE COVER-CLAMP on top, secured by SCR-HEX,5/16 threaded into hole in pivot pin, as shown. Tighten. Use (2) TIE-WIRE (3301358) around hoses to secure together and to bottom fitting on lift cylinder, as shown. Pull ties tight and cut off ends. Pull slack out of hoses up into LH Secondary Arm. Tools: ½” Socket / Ratchet / Wire Cutters

  37. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 37DATE: 9/8/08 3301158 3401068 / 3400102 Get (2) SCREW- BHCS 5/16-18 X 3/4 ZP (3401068), (2) WASHER-LOCK 5/16 SPLIT ZP (3400102) and (1) CLAMP-CABLE 3/4 (3301158). On Right side, insert SCREW- BHCS with WASHER-LOCK into pivot to secure WELD-PIN ROTATE CYL, as shown above. Tighten. On Left side, insert SCREW- BHCS with WASHER-LOCK and CLAMP-CABLE 3/4 into pivot to secure WELD-PIN ROTATE CYL, as shown above. Tighten. Tools: 5/32” Allen Wrench Parts: 3401068 / 3400102 / 3301158

  38. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 38DATE: 9/8/08 3401390 3400054 Get (2) SCR-SET,1/4-20X0.25 ZP (3400054). Apply drop of ND 121200-50 50 ML (BLUE LOCTITE 242) (3401390) to each SCR-SET. Thread (1) SCR-SET into each SUB-BLOCK ROTATION on right and left lift-arm cylinders, as shown. Tighten. Parts: 3400054 Tools: 1/8” Allen Wrench

  39. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 39DATE: 9/8/08 3335046 3400036 / 3400088 Get (1) PLT-SWITCH CONTACT, ROTATE (3335046) and attach to PIVOT-HOPPER LH with (2) SCR-HEX, 5/16-18x0.75 ZP (3400036) and (2) WASHER-FLAT 5/16 IDx.688 ODx.0 (3400088). Hand tighten. Parts: 3335046 / 3400036 / 3400088

  40. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 40DATE: 9/8/08 Insert (1) SCR-SET,1/2-20X3.00 ZP (3400404) through bottom of tab where RH Curb Broom is to be installed. Thread SCR-SET into weld-nut leaving the amount of threads shown above the top of the welded nut on the tab (approximately 1”). Thread (1) NUT-HEX JAM 1/2-20 ZP (3400449) onto bottom end of the SCR-SET as shown. If needed, tap out threads in weld-nut to clear paint before inserting SCR-SET,1/2-20X3.00 ZP. 1” Threads above weld-nut 3400404 3400449 Tools: ½ x13 Tap / 6mm Hex-Head Socket / Ratchet Parts: 3400404 / 3400449

  41. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 41DATE: 9/8/08 3307033 3307794 3307794 Get (1) ASSY-CURB BROOM SUB 8X/9X (3307033). Position the ASSY-CURB BROOM SUB to the front right of the unit aligning the tube on the bottom side of the broom assembly with the bracket on the unit as shown. Insert (1) PIN-CLEVIS 1/2 X 4-1/2 ZP (3307794) through from the outside of the frame, making sure the PIN goes through the tabs on the frame and the welded tube on the curb broom arm. Tap pin through. 3400086 Secure PIN-CLEVIS inside frame with (1) WASHER-FLAT 1/2 STANDARD ZP (3400086) and (1) PIN-COTTER 5/8 RUE-RING (3400124), as shown at right. 3400124 Parts: 3307033 / 3307794 / 3400086 / 3400124 Tools: Mallet

  42. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 42DATE: 9/8/08 4-Foot Sleeve 2-Foot Sleeve 4-Foot Sleeve Get (1) HOSE-HYD 1/2 X 84 451 TC ST#8 (3335249) and (1) HOSE-HYD 1/2 X 84 451 TC ST#8 (3335250) from the KIT - HOSE, MAIN 1900 (3335233). Cut 4-foot and 2-foot pieces of SLEEVE-HOSE NYLON 1"-1-1/8" (3500329). Insert straight-fitting ends of hoses through 4-foot sleeve. Insert 90-degree fitting ends of hoses through 2-foot sleeve and insert hoses in sleeve above brake bar through firewall to valve control assembly, as shown. Route straight-fitting ends of hoses in sleeve through hole in frame in front of wheel well, as shown. 3335250 3335249 Parts: 3335249 / 3335250 / 3500329 Tools: Electric Knife

  43. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 43DATE: 9/8/08 3335250 3335250 3335249 Connect straight fitting on Curb Broom Hose3335250 to outside fitting on curb broom. Connect straight fitting on Curb Broom Hose3335249 to inside fitting on curb broom. Tighten both hoses, mark and torque to 48 ft./lbs. Tools: 7/8” Torque Wrench / 13/16” Wrench / Red Paint Pen

  44. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 44DATE: 9/8/08 3500117 3302493 Get (2) TIE-WIRE BLACK (3302493) and use to secure sleeve to curb broom hoses together on top of curb broom motor and to curb broom arm, as shown. Pull ties tight and cut off ends. Cut 12” of EDGING-VINYL TRIM 3/16" X 250’ (3500117) and fit around hole in the frame in front of wheel well where hoses are routed, as shown. Cut to fit. Tools: Wire Cutters Parts: 3500117 / 3302493

  45. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 45DATE: 9/8/08 3400089 / 3400081 Get (3) TIE-WIRE BLACK (3302493). Use (1) TIE and secure end of sleeve to curb broom hoses together at connections to valve control assembly, as shown at left. Use (2) TIES secure ends of both sleeves on hoses where they are routed behind right end of the brake bar on top of wheel well, as shown at right. Pull ties tight and cut off ends. 3301437 3302493 3302493 Get (1) HOSE CLAMP-PLTD (3301437), (1) WASHER-FLAT 1/4 STANDARD ZP (3400089) and (1) NUT-HEX 1/4-20 ES ZP (3400081). Place curb broom hoses on each side of threaded stud in right-front corner inside frame behind brake bar. Use HOSE CLAMP-PLTD with WASHER-FLAT and NUT-HEX on stud to secure hoses. Tighten nut. Parts: 3302493 / 3301437 / 3400089 3400081 Tools: 7/16” Socket / Air Ratchet Wire Cutters

  46. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 46DATE: 9/8/08 Attach (1) SUB-CLOGGED FILTER JONAS 1900 (3335500) to the hopper side of the firewall on left side of impeller port where shown with (2) SCR-HEX,#10-32X0.50 ZP (3400315) and (2) NUT-HEX JAM #10-32 ES ZP (3400172). Insert screws through hopper side and secure with nuts on engine side. Tighten. 3400315 3335500 Parts: 3335500 / 3400315 / 3400172 Tools: Ratchet / 3/8” Socket / 3/8” Wrench

  47. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 47DATE: 9/8/08 3400035 3400384 3300351 3307767 Insert (1) HOSE-IMPELLER ARMA (3307767) onto the IMPELLER port on the hopper side, as shown. Get (2) CLAMP-HOSE 4 1/2" DIA (3300351) and place both on HOSE. Get (1) SUB-GASKET MOUNT, 1900 (3335404) and insert rear of mount into HOSE-IMPELLER. Place (2 ) WASHER-CONICAL SPRING 5/16 (3400384) onto (2) SCR-HEX,5/16-18X1.00 ZP (3400035) and insert through top of SUB-GASKET MOUNT, 1900 into the FRAME. Parts: 3307767 / 3300351 / 3335404 / 3400384 / 3400035

  48. 3400177 MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 48DATE: 9/8/08 3400035 / 3400384 3300351 Red fitting Place (1) clamp on hose at impeller port and other clamp at other end of hose at GASKET MOUNT ASSY, as shown. Tighten both clamps on impeller hose. Attach small hose included on the SUB-CLOGGED FILTER JONAS 1900 to the Red fitting on the side of the GASKET MOUNT ASSY, as shown above. Tighten (2) screws at top of gasket mount. Tools: Ratchet / Extension / 5/16” Socket / 1/2” Socket

  49. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 49DATE: 9/8/08 3400081 Get (1) SUB-SIDE BROOM LIFT RH, 1900 (3334939). Align the holes on the SIDE BROOM LIFT with bracket inside front-right of the FRAME. Insert (3) SCR-HEX,1/4-20X0.88 ZP (3400041) through the holes in the SIDE BROOM LIFT. Secure the SIDE BROOM LIFT to the FRAME with (3) NUT-HEX 1/4-20 ES ZP (3400081). Tighten. 3400041 3334939 Thread (1) NUT-HEX 3/8-24 ZP (3400067) onto end of (1) CABLE-SIDE BROOM, 33" LG, 1/8"D (3334946), then thread end of CABLE into ball joint on the end of the SUB-SIDE BROOM LIFT RH, 1900 as shown at left. Tighten NUT-HEX against ball joint. Route other end of CABLE-SIDE BROOM forward to curb broom. 3334946 3400067 Parts: 3334939 / 3400041 / 3400081 / 3400067 / 3334946 Tools: Ratchet / 7/16” Socket / 7/16” Wrench / 9/16” Wrench

  50. MODEL: 1900 JONAS - WC05DOCUMENTED BY: John MyersPAGE NUMBER: 50DATE: 9/8/08 3303552 3300367 Insert (1) SLEEVE-HAND BRAKE ZP (3303552) into (1) PULLEY-2.50 DIA, BUSHED, ¼" CABLE MAX, BRAKE (3300367). Place the PULLEY with SLEEVE in bracket above curb broom. Insert (1) SCR-HEX,5/16-18X1.25 ZP (3400034) with (1) WASHER-FLAT 5/16 IDx.688 ODx.065 THK (3400088) through outside of bracket and through PULLEY. Secure inside bracket with (1) NUT-HEX 5/16-18 ES ZP (3400080) on the back side of the PULLEY. Route the CABLE-SIDE BROOM, 33" LG, 1/8"D over the PULLEY. Insert (1) SCR-HEX,1/4-20X1.25 ZP (3400227) with (1) WASHER-FLAT 1/4 STANDARD ZP (3400089) through bracket above the PULLEY. Secure SCR-HEX with (1) NUT-HEX 1/4-20 ES ZP (3400081). Tighten. 3334946 3400227 / 3400089 3400081 3303552 / 3300367 3400080 3400034 / 3400088 Parts: 3303552 / 3300367 / 3400034 3400088 / 3400080 / 3400227 3400089 / 3400081 Tools: (2) 7/16” Wrenches / (2) 9/16” Wrenches

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