MODEL 1900 JONAS WC 09 DOCUMENTED BY John

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 1 DATE: 12/4/08 Authorized By: Assembly Instructions: 1900 JONAS WC – 09 (Station 9) Pages 1 -45 P: ISO 9001 2000Work InstructionsAssemblyMain Assembly LineJONAS 1900 AY 25 Rev 1

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 2 DATE: 1/7/09 3335540 Get (1) ID PLATE-SERIAL # INFO (ALUM DECAL) HAKO (3335540) and stamp required information about unit on label. Parts: English version for ID PLATE. Info on ID PLATE is same for all units except for Serial Number and Model: LPG or D for DSL. 3335540 Tools: Plate Stamping Machine IP X 3 MODEL NUMBER SERIAL NUMBER MACHINE WEIGHT (KG) FRONT WHEEL WEIGHT (KG) HAKO – JONAS 1900 LPG (or 1900 D) 6330 20 8 0101 1 2570 1800 KW 27 YE AR REAR WHEEL WEIGHT (KG) 2009 770

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 3 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. DATE: 11/25/08 3342258 3335540 3400441 Get (1) DECAL-HAKO MAIN BRM ADJ. 1800 (3342258) and (1) DECAL-DECIBEL LEVEL, MAX GRADE (3335628). Peel off backing and place on driver’s side of console, as shown. 3335628 Get 3335540 ID PLATE-SERIAL # INFO (ALUM DECAL) HAKO with unit information stamped on it and (4) RIVETS-POP 1/8 X 1/4 STEEL (3400441). Use pop-rivets to mount ID PLATE-SERIAL on driver’s side of console, as shown. Parts: 3342258 / 3335628 / 3400441 Tools: Rag / Isopropyl Alcohol / Pop Rivet Gun

MODEL: 1900 JONAS – WC 09 Shop Note: Clean all surfaces with Isopropyl Alcohol and DOCUMENTED BY: John Myers wipe dry with rag before applying decals. PAGE NUMBER: 4 3335553 DATE: 11/25/08 3335707 3342264 17269928 3342260 3342259 Get (1) DECAL-HOPPER SAFETY SWITCH (3335553), (1) DECALHAKO READ MANUAL 1800 (3342264), (1) DECAL-HAKO NO WASH AREA 1800 (3342259), (1) DECAL -KEY START (17269928), (1) DECAL-HAKO PARKING BRAKE 1800 (3342260) and (1) DECALSTEERING WHEEL ADJUSTMENT (3335707). Peel off backing and place decals on front of driver’s compartment as shown. Parts: 3335553 / 3342264 / 3342259 / 17269928 / 3342260 / 3335707

MODEL: 1900 JONAS – WC 09 Shop Note: Clean all surfaces with Isopropyl Alcohol and DOCUMENTED BY: John Myers wipe dry with rag before applying decals. PAGE NUMBER: 5 DATE: 11/25/08 3336032 For LPG Units, get (1) DECAL-1900 LPG (3336032) and apply to lintel above steering console, as shown. For DSL Units, get (1) DECAL -1900 DSL (17206251) and apply to lintel above steering console, as shown. Parts: 3336032 or 17206251

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 6 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. DATE: 11/25/08 3342263 Parts: 3342263 Get (1) DECAL-HAKO BRAKE 1800 (3342263) and apply on brake pedal as shown.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 7 DATE: 12/4/08 For All Units For LPG Units 3 inches 17200114 4 1/8 inches 17200114 Get (2) DECAL-HAKO LARGE 3 D RAISED LOGO (17200114). For All Units, place DECAL-HAKO LARGE 3 D RAISED LOGO on left-front (driver’s perspective) of hopper dump door and measure 4 1/8 inches from left edge of door to left-top corner of logo and measure 3 inches down from top edge of door to left-top corner of logo. Mark measurements and apply logo. Wipe off pencil marks. Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. For LPG Units, apply (1) DECAL-HAKO LARGE 3 D RAISED LOGO on left-rear of counterweight, as shown above. Parts: 17200114 Tools: Tape Measure / Pencil

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 8 DATE: 12/4/08 For DSL Units 17261553 17200114 For DSL Units, apply (1) DECAL-HAKO LARGE 3 D RAISED LOGO on right-rear of counterweight as shown above. Apply (1) DECAL-DIESEL (17261553) on top of filler cap on fuel tank, as shown. Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. Parts: 17261553

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 9 DATE: 11/25/08 17268871 Get (2) DECAL - CAUTION, ROTATING OBJECTS (17268871) and apply (1) decal to each filter shaker motor, as shown. Parts: 17268871 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 10 DATE: 11/25/08 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. For LPG Units 3301733 3342106 3342978 Parts: 3342106 / 3342978 / 3301733 For LPG Units: Get (1) DECAL-ORANGE COOLANT (3342106) and apply to top of radiator, as shown. Get (1) DECAL-HOT SURFACE 1800 (3342978) and apply to side of radiator top, as shown. Get (2) DECAL-WARNING FAN (RAD SHROUD) (3301733) and apply to top of radiator, as shown

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 11 DATE: 11/25/08 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. For DSL Units 3301733 3342978 3342106 Parts: 3342106 / 3342978 / 3301733 For DSL Units: Get (1) DECAL-ORANGE COOLANT (3342106) and apply to top of radiator, as shown. Get (1) DECAL-HOT SURFACE 1800 (3342978) and apply to bracket on top of radiator, as shown. Get (2) DECAL-WARNING FAN (RAD SHROUD) (3301733) and apply to radiator fan shroud, as shown.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 12 DATE: 11/25/08 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. For DSL Units: Get (1) DECAL-HOT SURFACE 1800 (3342978) and apply to heat shield on right side of engine, as shown. Parts: 3342978

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 13 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. DATE: 11/25/08 3342105 3342650 Get (2) DECAL-5550 LATCH SECURELY (3342105) and (1) DECAL-HAKO PINCH POINT 1800 (3342650). Peel off backing and apply as shown on left side of frame and on engine swing frame. Parts: 3342105 / 3342650

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 14 LPG Units Only DATE: 11/25/08 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. 3342269 3342971 For LPG Units, get (1) DECAL-HAKO NO VAPOR LP TANKS 1800 (3342269) and (1) DECAL-WARNING (EXPLOSIVE FUEL) (3342971). Peel off backing and place as shown at rear of LP Tank compartment. Parts: 3342971 / 3342269

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 15 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. DATE: 11/25/08 3342650 Get (2) DECAL-HAKO PINCH POINT 1800 (3342650). Peel off backing and apply as shown on outside of secondary lift arms, one on each side. Parts: 3342650

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 16 DATE: 11/25/08 For LPG Units: Get (1) DECALHAKO HYDRAULIC FLUID 1800 (3342266) and (1) DECAL-HYD OIL DTE-15 M VG 46 (3335987) and place on top of hydraulic fill tube, as shown. Parts: 3342266 / 3335987 3342266 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 17 DATE: 11/25/08 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. 3335987 For DSL Units 3342266 For DSL Units: Get (1) DECAL-HAKO HYDRAULIC FLUID 1800 (3342266) and (1) DECALHYD OIL DTE-15 M VG 46 (3335987) and place on top of hydraulic fill tube, as shown. Get (1) DECAL-WARNING TANK (3301728) and place on top of fuel tank, as shown. Parts: 3342266 / 3335987 / 3301728

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 18 DATE: 11/25/08 3335897 Remove WELD-COVER FUSE BOX 1900. Get (1) DECAL-MAIN FUS BOX LAYOUT, 1900 (3335897) and apply inside cover, as shown. Replace cover. Parts: 3335897 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 19 DATE: 11/25/08 3335898 Remove fuse panel cover. Get (1) DECAL-MAIN FUSE BOX ACCESS, 1900 (3335898) and apply inside cover, as shown. Replace cover. Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. Parts: 3335898

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 20 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals. DATE: 11/25/08 1726890 Parts: 17268970 Get (1) DECAL -SIDE BROOM ADJUSTMENT (17268970) and apply to HD Curb Broom as shown.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 21 DATE: 11/25/08 3335554 Get (2) DECAL-MAX TIRE PRESSURE (3335554) and apply one decal above each front wheel on the frame, as shown. Parts: 3335554 Shop Note: Clean all surfaces with Isopropyl Alcohol and wipe dry with rag before applying decals.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 22 DATE: 11/25/08 After applying all large decals, drive unit to Final Inspection Area without installing PANELFLOORBOARD, MAIN, 1900, as shown, or COVERRUBBER, DUST CURTAIN inside front of unit under hopper.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 23 DATE: 11/25/08 Final audit inspector first checks all paperwork with unit is complete and correct. Inspector then checks levels of all vital fluids and performs all safety checks. All hydraulic functions are tested, including raising and lowering the hopper. Inspector then drives unit for 20 minutes and performs all driving tests. Inspector removes curb broom and main broom for final inspection process.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 24 DATE: 11/25/08 After driving tests, technician drives unit onto floor lift and raises machine to continue checking under machine for fluid leaks and all remaining items on QA Check List.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 25 DATE: 11/25/08 QA technician marks all items on check list as passed satisfactorily or requiring correction on assembly line to pass final inspection. Unit is then driven back to assembly line. After final inspection, all items noted on QA Check List as needing correction are fixed on assembly line. After all items requiring fix on assembly line are completed, unit is driven back to Final Inspection Area to be checked again by QA technician. All items requiring action are inspected again by QA technician. When all items on QA Check List are passed and marked complete, unit is driven back to assembly line for final assembly work.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 26 DATE: 11/25/08 After final inspection is completed, use high-pressure air hose to blow out all metal shavings and any other trash from inside areas of unit, including under floor pan around valve control assembly, under seat in LP Tank compartment or fuel tank compartment and around and under both sides of engine in engine compartment. Tools: Air Hose Nozzle

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 27 DATE: 11/25/08 Drive unit to wash area. Raise hopper. Wash all surfaces on outside of unit including under hopper. Lower hopper and wash outside of hopper and front bumper. After washing, unit is driven back to assembly line for final assembly items.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 28 3336033 DATE: 11/25/08 Get (1) DECAL-ELECTRICAL SCHEMATIC LABELS (3336033). Parts: 3336033

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 29 DATE: 11/25/08 H 10 S 9 S 10 Apply S 9 label to rear switch on SUB-LIFT SWITCH and apply S 10 label to front switch. Apply H 10 label beside horn and B 5 label beside Clogged Filter Switch. B 5

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 30 DATE: 11/25/08 Apply B 4 label inside gasket mount for impeller intake. B 4

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 31 DATE: 11/25/08 P 1 S 0 Apply S 0 label under ignition switch inside right-front of lintel. Apply P 1 label above large round gauge inside lintel.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 32 DATE: 11/25/08 M 2 S 16 Apply M 2 label on actuator bracket inside right side of frame at front. Apply S 16 label on side of parking brake inside front of unit.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 33 DATE: 11/25/08 F 0 On top of fuse panel cover on side of battery box in engine compartment, apply F 0 label to top and F 18 label to bottom, as shown. F 18

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 34 DATE: 11/25/08 S 11 S 8 S 5 Apply S 8 label on side of engine switch assembly in engine compartment. At front end of LH Rotation Arm on SUB-ROTATION SWITCH, apply S 11 label on plate next to top switch and apply S 5 label on plate next to bottom switch.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 35 DATE: 11/25/08 Y 9 DSL Units Only B 3 For DSL Units Only: Apply B 3 label next to sending unit on top of fuel tank, as shown above. On left side of DSL engine, apply Y 9 label next to Fuel Shutoff Solenoid, as shown at top right. Apply Y 11 label next to Throttle Solenoid, as shown at bottom right. Y 11

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 36 DATE: 11/25/08 S 1 P 2 Inside console, apply S 1 label as shown. Beside Hour Meter inside console, apply P 2 label as shown. Shop Note: Cut “ 4” off S 14 decal to create S 1 decal. Tools: Scissors

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 37 DATE: 11/25/08 Shop Note: View below shown from front of valve control assembly. Y 4 Y 6 Y 3 Y 7 Y 5 Y 2 Y 1 On plugs on right side of valve control assembly, apply Y 1 label to bottom, Y 2 label to middle and Y 3 label to top. To plugs at bottom of valve control assembly, from left (driver’s perspective) apply Y 4 label to plug on left, apply Y 5 to next plug, apply Y 7 to next plug and apply Y 6 label to plug on right.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 38 DATE: 11/25/08 S 22 S 23 H 9 In floor board on SUB-DBL LIMIT SWITCH, FWD/REV, 1900 apply S 22 label next to to switch on left and apply S 23 label next to to switch on right. Beside backup alarm inside frame at rear, apply H 9 label.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 39 DATE: 11/25/08 B 2 M 6 M 7 On side of engine on starter Red boot, apply M 6 label. On side of engine on alternator Red boot, apply M 7 label. On side of harness connected to Water Temperature Sender, apply B 2 label.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 40 DATE: 11/25/08 On right side of engine on side of Oil Pressure Sender, apply B 1 label, as shown. B 1

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 41 DATE: 11/25/08 M 4 M 1 Inside hopper, on bar in front of left-side filter shaker motor, apply M 4 label and on bar in front of right-side shaker motor, apply M 1 label.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 42 DATE: 11/25/08 S 25 S 12 On bottom of seat, beside harness apply S 25 label. On side of switch in tilt-steering console, apply S 12 label.

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 43 DATE: 11/25/08 3335179 3335618 3335563 3335180 3401452 3335617 Get (1) PANEL-FLOORBOARD, MAIN, 1900 (3335179) and place on top of 3335180 WELD-FLOORBOARD, FWD, 1900, as shown above. Get (1) PAD-BASEBOARD, ANIT-SKID, 1. 5" X 8" (3335616), (1) PLATEBASEBOARD, RH (3335617), (1) PLATEBASEBOARD, LH (3335618), (1) MAT-FLOORBOARD, RUBBER DIA PLT (3335563) and (9) SCR-TRUSS HEAD 5/16 X 1. 0 PH ZP (3401452). Parts: 3335616 Place MAT-FLOORBOARD on top of floorboards. Place PLATE-BASEBOARD, RH on right side and PLATEBASEBOARD, LH on left side. Secure with SCRS-TRUSS HEAD and tighten. Peel backing off PAD-BASEBOARD and apply to PLATE-BASEBOARD, RH as shown above. 3335179 / 3335616 / 3335617 / 3335618 / 3335563 / 3401452 Tools: Phillips Screwdriver

3335723 MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 44 DATE: 11/25/08 3335722 3335721 3335723 3335721 3400081 3335722 Get (1) COVER-RUBBER, DUST CURTAIN (3335722), (1) PLT-DUST COVER CLAMP, 3 HOLE (3335723), (1) PLT-DUST COVER CLAMP, 2 HOLE (3335721) and (5) NUT-HEX 1/4 -20 ES ZP (3400081). Place COVER-RUBBER, DUST CURTAIN under lintel at front of unit with 5 -hole side at top and 4 -hole side at bottom. Insert 5 holes in COVER-RUBBER, DUST CURTAIN at top on 5 studs under lintel. On right side (driver’s perspective) place PLT-DUST COVER CLAMP, 3 HOLE on studs behind curtain. On left side, place PLT-DUST COVER CLAMP, 2 HOLE on studs. Secure with NUT-HEX 1/4 -20 ES ZP on each stud and tighten. Parts: 3335722 / 3335723 / 3335721 / 3400081 Tools: 7/16” Socket / Air Ratchet / 7/16” Wrench

MODEL: 1900 JONAS – WC 09 DOCUMENTED BY: John Myers PAGE NUMBER: 45 DATE: 11/25/08 Insert (4) holes in bottom of COVER-RUBBER, DUST CURTAIN over (4) plastic buttons across frame on front side of main broom chamber, as shown. 3300306 Main broom Reinstall main broom, which was removed during final inspection. Get (1) BROOM-SIDE 24" DIA. BLACK POLY (3300306) and install as replacement for testing curb broom removed during final inspection. This completes all assembly. Drive machine to palletizing area. Parts: 3300306