Kleinn Air Horns TJXTREME, Installation Manual

Page 1: ...TJXTREME INSTALLATION MANUAL Kleinn Air Horns 2020 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web www Kleinn com REV A 5 8 2020...

Page 2: ...stallation and Operation Manual Go to Table of Contents PG 2 36 REV A 5 8 2020 This digital PDF is interactive Please save ink and paper Open interactive manual using Adobe Reader on PC MAC and all sm...

Page 3: ...upplies 12 6 1 Standard Tool List Required 12 6 2 Special Tool List Recommended 12 6 3 Shop Consumables List Recommended 12 7 Parts List 13 7 1 Before Starting Review Parts List 13 7 2 Pre Packaged El...

Page 4: ...Fuse Diagram for Air Horn System 30 10 2 Suggested Wire Routing for Air Horn System 31 10 3 Disconnect Vehicle Battery s 31 10 4 Connect Wiring to Fuse and Relay route through Vehicle 31 10 5 Install...

Page 5: ...iver s Seat Rear Mounting Bolts 2001 Wrangler Sahara shown 23 Figure 11 Installing Driver s Seat Rear Mounting Bolts Exploded View 23 Figure 12 Holes Drilled using Guide Plate TJ 001 Rear Seat Carpet...

Page 6: ...it SKU Number and this Manual This manual covers installation testing and operation of following SKU part numbers 2 2 1 TJXTREME i e 220 Train Horn with On Board Air System NOTE Illustrations and pict...

Page 7: ...ibly rusted and sharp vehicle parts Before starting obtain proper tools required to perform installation correctly adequate lighting eye protection hearing protection for operating train horns and han...

Page 8: ...ctions on how to accomplish relocation Jeep TJ LJ Forum OE Locker Compressor Relocation 4 3 Aftermarket Product Compatibility 4 3 1 This kit has been designed to be compatible with following products...

Page 9: ...Side in front of Rear Axle below floor Bracket bolts through rear floor cross brace 1 2 Hours 2 1 5 Gal Air Tank Underbody Driver Side behind T Case below floor Bracket bolts onto upgraded seat bolts...

Page 10: ...TJXTREME Installation and Operation Manual Go to Table of Contents PG 10 36 REV A 5 8 2020 Figure 3 Under Vehicle of Actual Kit Installed 1999 Sport with Aftermarket Exhaust TJXTREME Shown FRONT FRONT...

Page 11: ...all Air Tank Bracket TJ 201 over 2X Seat Bolts leave slightly loose 11 Install Horn Compressor sub assembly over 2X Flange Lock Nuts attach to Tank Bracket TJ 201 12 Final tighten Brackets TJ 101 TJ 2...

Page 12: ...icial 6 2 2 3 16 Metal cutting drill Bit 2 long minimum 6 2 3 5 16 Metal cutting drill Bit 2 long minimum or variable sized Step Drill Uni bit 6 2 4 10 100 ft lbs torque wrench 6 2 5 20 150 in lbs tor...

Page 13: ...ng and Accessories i e E1 E2 etc 7 1 4 Review Bolt On Mounting Brackets i e M1 M2 etc 7 1 5 Review Hardware Fasteners i e H1 H2 etc 7 1 6 Familiarize yourself with how parts assemble 7 2 Pre Packaged...

Page 14: ...52175 view location on Air Tank 1 4 NPT 175 PSI SAFETY VALVE F3 2 51414L view location on Air Tank 1 4 NPT X 1 4 TUBE FITTING MALE 90 DEG ELBOW F4 1 51414NPTL view location on Air Tank 1 4 NPT X 1 4...

Page 15: ...4 AIR TUBING 12 FT LONG F10 1 KLEINN AIR HORN JUICE THREAD SEALENT FOR NPT FITTINGS 7 4 Electrical Small Components and Related Items ITEM QTY PART NUMBER DESCRIPTION PICTURE E1 1 6850 WIRE KIT FULL...

Page 16: ...201 TANK BRACKET CUT FORMED WELDED 7 6 Hardware Fasteners and Soft Parts NOTE Pictures only indicative not to scale and may not represent exact item ITEM QTY PART NUMBER SIZE DESCRIPTION PICTURE H1 1...

Page 17: ...IAGE BOLT GRADE 2 ZINC PLATED H8 2 5 16 18 FLANGE LOCK NUT GRADE 2 ZINC PLATED DO NOT USE ON ITEM H4 H9 11 5 16 18 X 1 00 LONG SQUARE NECK BOLT GRADE 2 ZINC PLATED H10 13 5 16 ID X 0 88 OD FLAT WASHER...

Page 18: ...020 7 7 Add On Accessories ITEM QTY PART NUMBER DESCRIPTION PICTURE X1 1 1302 QUICK COUPLER MOUNT KIT BRACKET HARDWARE FITTINGS 1 4 X 15FT AIR TUBING X2 1 INF 1 INFLATOR KIT COIL AIR HOSE QUICK CONNEC...

Page 19: ...h male pipe thread 8 1 3 Attach Air Fittings to Air Tank per below illustrations ensure they are oriented correctly Click Here to View Fittings List Figure 4 Air Fittings installed on Air Tank Top Exp...

Page 20: ...se assemble air filter to end of Compressor filter shown installed in figure below Follow instructions included in Compressor package 8 2 3 Using included hardware and Hardware H13 install Compressor...

Page 21: ...xploded View 8 4 Assemble Air Horn Drivers to Bracket TJ 101 8 4 1 Using Hardware H9 H10 H11 H12 H13 install Air Horn Drivers as shown below Snug tighten fasteners only as Drivers may need to be repos...

Page 22: ...Compression Fitting F8 8 5 4 If desired at this time secure Leader Hose and Fitting to Bracket using supplied Zip Ties as shown below Figure 9 Air Tubing Connections View Showing Complete Assembly as...

Page 23: ...s latch 9 1 2 Open rear flaps and remove both Inboard and Outboard Bolts as shown below OE bolts are not re used Figure 10 Driver s Seat Rear Mounting Bolts 2001 Wrangler Sahara shown 9 1 3 Install Ha...

Page 24: ...erpendicular so holes drilled through lower brace are directly in line with holes in floor If holes are not inline Compressor Bracket may not fit properly 9 2 4 Remove Guide Plate and re install OE Se...

Page 25: ...p head to begin seating too much force may damage floor 2 From below vehicle temporarily use Hardware H10 H12 to seat Ribbed Neck Bolts into vehicle floor by tightening Nuts firmly remove Washer and N...

Page 26: ...pgraded Seat Bolts as shown below Use Hardware H3 H6 and loosely tighten Nuts by hand final tightening will occur later Recommended to apply medium strength Loctite to threads NOTE Place outboard side...

Page 27: ...emporarily moved if it interferes with Bracket install 9 5 2 While holding Sub Assembly in place install Hardware H9 H10 H11 H12 as shown below It is recommended to apply medium strength Loctite to fa...

Page 28: ...ast 1 4 of clearance exists between Air Tank fitting and Shaft throughout entire 360 deg rotation Final torque fasteners to 75 in lbs CAUTION It is paramount to ensure that Air Tank Safety Valve is pr...

Page 29: ...g Trumpets Exploded View No Air Tubing Shown 9 9 Install 1302 Remote Connect Coupler to Vehicle 9 9 1 Remove Quick Connect Coupler Rubber Cover from F11 INF 1 Air Hose Bag 9 9 2 Decide where on vehicl...

Page 30: ...ed safety precautions for working on vehicle s electrical system consult vehicle owner s manual for further instruction 10 1 Relay and Fuse Diagram for Air Horn System Figure 20 Suggested Ignition Rel...

Page 31: ...Air Compressor and Pressure Switch TJXTREME Shown 10 3 Disconnect Vehicle Battery s 10 3 1 Consult Owner s Manual 10 4 Connect Wiring to Fuse and Relay route through Vehicle 10 4 1 Find a suitable lo...

Page 32: ...nal to one end and Butt connector on other end CAUTION Do not install 30 amp fuse until all electrical connections are final 10 5 Install Horn Button 10 5 1 Find a suitable location for horn push butt...

Page 33: ...g Install push button into hole and tighten retaining nut from backside 10 6 Connect Pressure Switch 10 6 1 Route wiring as desired back to Air Tank and connect to Pressure Switch per wiring diagram 1...

Page 34: ...le brackets or kit parts if necessary use extra zip ties to hold tubing and wire in place 11 3 3 Ensure all nearby persons have adequate hearing protection and provide courtesy warning to neighbors or...

Page 35: ...t once during recommended intervals 13 1 Yearly or every 12000 miles verify all mounting fasteners are properly torqued applying witness marks across fasteners and mounting parts is good practice to q...

Page 36: ...tion Thank you for purchasing TJXTREME Shall you experience any unexpected problems during installation or have problems with any part at any time please contact Kleinn support End of Technical Manual...