Kleinn Air Horns CANX3-KIT Installation Manual Download Page 2

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CANX3-KIT

Installation and Operation Manual

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REV: A (9/4/2020)

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Summary of Contents for CANX3-KIT

Page 1: ...CANX3 KIT INSTALLATION MANUAL Kleinn Air Horns 2020 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web www Kleinn com INCLUDES CALIFORNIA CARB VEHICLES REV A 9 4 2020...

Page 2: ...stallation and Operation Manual Go to Table of Contents PG 2 44 REV A 9 4 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: ...Installation Time 10 6 List of Tools and Supplies 11 6 1 Standard Tool List Required 11 6 2 Special Tool List Recommended 11 6 3 Shop Consumables List Recommended 11 7 Parts List 12 7 1 Before Starti...

Page 4: ...Relay and Fuse Diagram for Air Horn System 39 9 2 Review suggested Wire Routing for Air Horn System 40 9 3 Disconnect Vehicle Battery s 40 9 4 Connect Wiring to Relay s and Fuse s then Attach to Vehic...

Page 5: ...Version shown 29 Figure 19 Air Compressor Bracket Mounting Locations top view 29 Figure 20 Installing Air Compressor Bracket Exploded View 30 Figure 21 Air Compressor positioned temporarily in place S...

Page 6: ...is Manual This manual covers installation testing and operation of following SKU part numbers 2 2 1 CANX3 KIT i e 102b Train Horn with On Board Air System 2 2 2 CANX3 OBA i e On Board Air System NOTE...

Page 7: ...sibly 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 ha...

Page 8: ...following products from leading manufacturers Aftermarket cages that discard OE rearmost bolt on chassis tubes i e Rack down tubes Aftermarket front shock tower braces and bulkheads i e S3 PowerSports...

Page 9: ...Tank Brackets X3 201 202 203 204 5 Bench assemble Air Fittings and Air Tubing to Air Tank 6 Install Air Tank 7 Bench assemble Air Compressor Bracket X3 101 8 Bench assemble Air Compressor and Leader H...

Page 10: ...de behind fender and below Rack 1 2 Hours 3 102 Series Dual Horn with Air Solenoid Front Sway bar Mounts directly behind front shocks 2 4 Hours Figure 1 Top View Showing Kit Layout 2018 X3 2 Door Show...

Page 11: ...9 Utility Knife or Utility Razor blade 6 1 10 Magnetic retrieval tool 6 2 Special Tool List Recommended 6 2 1 10 100 ft lb torque wrench 6 2 2 20 150 in lb torque wrench 6 2 3 Multi Meter for 12V DC e...

Page 12: ...2 etc 7 1 3 Review Wiring 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 ass...

Page 13: ...WITCH F2 1 54440 view location on Air Tank 1 4 NPT T MANIFOLD FEMALE F3 2 51414NPTL view location on Air Tank 1 4 NPT X 1 4 NPT FEMALE 90 DEG ELBOW F4 1 52835 view location on Air Tank 1 4 NPT DRAIN V...

Page 14: ...FT FOR COMPRESSOR 14 FT FOR AIR HORN F10 1 KLEINN AIR HORN JUICE THREAD SEALENT FOR NPT FITTINGS F11 1 INF 1 INFLATOR KIT WITH AIR HOSE AND BAG 7 4 Electrical Small Components and Related Items ITEM Q...

Page 15: ...KER SWITCH WITH BACKLIT HORN LOGO 7 5 Bolt On Mounting Brackets Special Hardware ITEM QTY PART NUMBER DESCRIPTION PICTURE M1 1 X3 101 COMPRESSOR BRACKET WELDMENT M2 1 X3 102 LEADER HOSE SUPPORT BRACKE...

Page 16: ...2 HORN STABILIZER BRACKET CUT AND FORMED 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...

Page 17: ...UARE NECK BOLT GRADE 2 ZINC PLATED H7 4 5 16 ID X 0 88 OD FLAT WASHER USS ZINC PLATED H8 7 5 16 ID X 0 69 OD FLAT WASHER SAE ZINC PLATED H9 11 5 16 LOCK WASHER SPLIT ZINC PLATED H10 11 5 16 18 HEX NUT...

Page 18: ...0 8 X 10MM LONG BUTTON HEAD CAP SCREW BLACK OXIDE H15 8 1 4 ID X 0 63 OD FLAT WASHER SAE BLACK OXIDE H16 2 M6 LOCK WASHER SPLIT BLACK OXIDE H17 2 1 1 16 OD X 1 2 ID X 3 8 WIDTH PRESS IN RUBBER GROMMET...

Page 19: ...of Brackets in any way voids their warranty 8 2 Remove Passenger side Rear Fender 8 2 1 Remove seven 7 T30 screws from top of fender and corner trim as shown circled in below figure 8 2 2 After removi...

Page 20: ...brake light as shown below Figure 4 Passenger Rear Fender Removal below tail light 8 2 5 Pull fender outwards from body and rest on tire to reduce stress on Brake Light Wiring as shown below Figure 5...

Page 21: ...ation 8 4 1 Gather Brackets X3 201 X3 202 X3 203 and X3 204 2 8 4 2 On passenger side of vehicle remove two 2 bolts holding Rack as shown below Do not discard large bolt as it will be re used Smaller...

Page 22: ...ll be rotated and moved along tube NOTE Ensure forward edge of clamp is butted against weld bead on chassis which increases clearance between back of X3 203 and springs There should be a minimum clear...

Page 23: ...en use a magnetic tool to hold Coupling Nut and Washer together and insert them into Support Tube Figure 10 Installing Rear Air Tank Bracket Exploded View 8 4 5 Ensure Coupling Nut and Washer are corr...

Page 24: ...are oriented exactly as shown Click Here to View Fittings List Figure 12 Air Tank Fittings installed on Air Tank Exploded View 8 5 4 Hand tighten each fitting then further tighten 1 4 1 2 turn using...

Page 25: ...Air Tank then final torque front Bracket per figure 10 above 8 6 3 Install Air Tank onto Brackets using hardware H5 H7 H9 H10 as shown below NOTE Position Air Tank and Brackets as necessary to mainta...

Page 26: ...Apply adequate Kleinn Air Horn Juice to end of Leader Hose and attach Air Fitting F8 to end of Leader Hose as shown below Do NOT overtighten fitting which could damage check valve See instructions in...

Page 27: ...to Compressor as shown below Hex bolts are threaded from front to back Recommended to apply Medium Strength Loctite i e Blue to threads before installing then Torque to 20 in lbs Figure 16 Air Compre...

Page 28: ...ss sleeves into Compressor Bracket as shown below in Figure 17 and Figure 20 Figure 17 Air Compressor Bracket with Rubber Grommets Installed RUBBER BUSHINGS BRASS SLEEVES FROM COMPRESSOR FEET INSTALL...

Page 29: ...ont bolt holding Rack as shown below M6 bolt and nut i e front bolt will be replaced and may be discarded 8 9 3 Remove rear bolt holding Rack same as Figure 6 Do not discard this bolt it will be re us...

Page 30: ...able Bracket to be re positioned as needed Figure 20 Installing Air Compressor Bracket Exploded View 8 9 5 Temporarily install Air Compressor onto Bracket by inserting Compressor Bolts through Brass S...

Page 31: ...ure 22 Air Compressor Clearance Adjustment Shown installed on CARB Vehicle 8 9 7 Remove Air Compressor from Bracket and set aside This is necessary to gain proper access to Hex Coupling nut i e H12 in...

Page 32: ...esired There should be at least 12 inches of excess tubing sticking out of Driver s side to manipulate and connect to Air Compressor Once route is selected secure Air Tubing in place WARNING Route pla...

Page 33: ...s Connect previously routed 1 4 Air Tubing to Leader Hose end and secure all Air Tubing using supplied zip ties Figure 25 Installing Air Compressor onto Bracket Exploded View shown without Leader Hose...

Page 34: ...X3 301 Horn Bracket hardware H5 2 and a 4 long piece of masking tape or similar and temporarily tape carriage bolts to bottom of Bracket as shown below threads should be sticking up NOTE This step is...

Page 35: ...gated wire loom E4 into two 6 long pieces and fit over Coolant Tubes as shown in figure above Re adjust loom position as necessary to provide protection from Bracket touching 8 11 6 Install X3 301 by...

Page 36: ...pet Support Clamp and Insert Trumpets using hardware H8 H9 H10 Loosely tighten hardware so X3 302 can still be positioned Once hardware is installed remove tape holding bottom side of carriage bolts t...

Page 37: ...s desired NOTE It may be necessary to reconnect Trumpets to Air Horn Driver before installing hardware Figure 33 Installing Air Horn Driver with Tubing attached Exploded View 8 11 9 With Trumpets and...

Page 38: ...ow pictures Figure 35 Final installation of 102 Air Horn X3 Turbo R shown 8 12 Connect Remote Quick Connect Kit to Vehicle 8 12 1 Route and attach Quick Connect Coupler Kit to vehicle as desired using...

Page 39: ...On Vehicle Electrical Installation CAUTION Follow all recommended safety precautions for working on vehicle s electrical system consult vehicle owner s manual for further instruction 9 1 Relay and Fu...

Page 40: ...Remove Passenger side seat or move it forward to expose Battery Consult Owner s Manual 9 4 Connect Wiring to Relay s and Fuse s then Attach to Vehicle 9 4 1 Find a suitable location for supplied relay...

Page 41: ...e final 9 5 Install Horn Button 9 5 1 It s recommended to install Horn Push Button E5 in OE location designed for aftermarket switches and accessories found at center console as shown below Figure 40...

Page 42: ...ned to vehicle brackets or kit parts if necessary use extra zip ties to hold tubing and wire in place 10 3 3 Ensure all nearby persons have adequate hearing protection and provide courtesy warning to...

Page 43: ...ommended intervals 12 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 quickly ensure fas...

Page 44: ...ty Information Thank you for purchasing this CANX3 KIT Shall you experience any unexpected problems during installation or have problems with any part at any time please contact Kleinn support Kleinn...

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