Kleinn Air Horns X3-KIT Installation Manual Download | Manualshive

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X3-KIT

Installation and Operation Manual

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PG 20/40

REV: BETA (4/25/2019)

8.2.4.

Remove single T15 screw holding rear of fender near inside of 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

–

Passenger Rear Fender Removal (fender resting on tire); Air Tank shown installed

T15 Screw

FRONT

Brake Light

Wiring Still
Connected

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Summary of Contents for X3-KIT

Page 1: ...X3 KIT INSTALLATION MANUAL Kleinn Air Horns 2019 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web www Kleinn com REV BETA 4 25 2019 ...

Page 2: ...allation and Operation Manual Go to Table of Contents PG 2 40 REV BETA 4 25 2019 This digital PDF is interactive Please save ink and paper Open interactive manual using Adobe Reader on PC MAC and all smart devices ...

Page 3: ...te 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 Starting Review Parts List 12 7 2 Pre Packaged Electro Mechanical Kit Items 12 7 3 Air Fittings and Related Items 13 7 4 Electrical Small Components and Related Items 14 7 5 Bolt On Mounting Brackets Spec...

Page 4: ...suggested Wire Routing for Air Horn System 36 9 3 Disconnect Vehicle Battery s 36 9 4 Connect Wiring to Relay s and Fuse s then Attach to Vehicle 36 9 5 Install Horn Button 37 9 6 Connect Air Horn Solenoid s 37 9 7 Pressure Switch 37 10 Initial Testing of Kit 38 10 1 Reconnect Vehicle Battery s 38 10 2 Test Air Compressor 38 10 3 Test Train Horns 38 10 4 Test Quick Connect Coupler 38 10 5 Re insta...

Page 5: ...26 Figure 17 Front Air Compressor Bracket stops at corner Gusset Shown with Air Compressor 27 Figure 18 Installing Air Compressor Bracket Exploded View 27 Figure 19 Air Tubing Route from Air Compressor to Air Tank 28 Figure 20 Installing Air Compressor Leader Hose Adapter Bracket 28 Figure 21 Installing Air Compressor onto Bracket Exploded View 29 Figure 22 Air Compressor Filter Remote Tubing show...

Page 6: ...d this Manual This manual covers installation testing and operation of following SKU part numbers 2 2 1 X3 KIT i e 102b Train Horn with On Board Air System 2 2 2 X3 OBA i e On Board Air System NOTE Illustrations and pictures contained herein may represent only one kit part number Where critical differences exist between kits i e different parts orientation mounting points etc additional text or ne...

Page 7: ...ssibly 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 hand protection to guard against sharp edges and metal burrs which may be present on kit parts and vehicle parts Throughout this manual the following words may be used be aware of their meaning and app...

Page 8: ...lowing products from leading manufacturers Aftermarket cages that discard OE rearmost bolt on chassis tubes i e rear deck down tubes Aftermarket front shock tower braces and bulkheads i e S3 PowerSports which bolt ONLY in front of shocks or below frame i e cannot attach above sway bar bolts 4 3 2 This kit has NOT been designed to be compatible with any of the following products Exhaust systems or ...

Page 9: ... Install Air Tank Brackets X3 201 202 203 204 5 Bench assemble Air Fittings and Air Tubing to Air Tank 6 Install Air Tank 7 Install Air Compressor Brackets X3 101 X3 204 8 Bench assemble Air Compressor Leader Hose Bracket X3 102 to Air Compressor 9 Install Air Compressor 10 Prepare Front Sway Bar area for Air Horn 11 Install Air Horn Brackets X3 301 302 12 Install Air Horn 13 Connect air lines and...

Page 10: ...Side behind fender and below rear deck 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 Shown 5 3 Approximate Installation Time X3 KIT is a multi faceted product consisting of multiple mechanical electrical and pneumatic components For a typical home mechanic auto enthusiast or techni...

Page 11: ...1 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 electrical systems or equivalent 6 2 4 12V DC Test Light or equivalent 6 2 5 Trim Panel Tool for removing wiring and body clips when needed 6 3 Shop Consumables List Recommended 6 3 1 Quality Electri...

Page 12: ... F2 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 assemble 7 2 Pre Packaged Electro Mechanical Kit Items NOTE Items in this section come in their own packages and may include additional items inside package ITEM QTY PART NUMBER DESCRIPTION PICTURE K1 ...

Page 13: ...RE SWITCH F2 1 54440 view location on Air Tank 1 4 NPT T MANIFOLD FEMALE F3 2 59014 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 VALVE F5 1 52175 view location on Air Tank 1 4 NPT 175 PSI SAFETY VALVE F6 1 51414 view location on Air Tank 1 4 NPT X 1 4 TUBE FITTING STRAIGHT F7 2 51414L view location on Air Tank 1 4 NPT X 1 4 TUBE...

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 QTY PART NUMBER DESCRIPTION PICTURE E1 1 WIRE KIT FULL WIRE KIT WITH ELECTRICAL CONNECTORS AND ZIPTIES E2 1 1 8 OD X 15FT LONG 1 8 WIRE LOOM CORRUGATED AND SPLIT E3 1 1 4 OD X 15FT LONG 1 4 WIRE LOOM ...

Page 15: ...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 OUTER HALF WELDMENT M2 1 X3 102 LEADER HOSE ADPATER BRACKET CUT M3 1 X3 201 TANK BRACKET REAR MOUNT CUT AND FORMED M4 2 X3 202 TANK BRACKET FRONT INNER HALF CUT AND FORMED M5 1 X3 203 TANK BRACKET FRONT OUTER HALF WELDMENT ...

Page 16: ...302 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 H1 2 1 4 20 X 1 SQUARE NECK BOLT GRADE 2 ZINC PLATED H2 2 1 4 ID X 0 63 OD FLAT WASHER SAE ZINC PLATED H3 2 1 4 LOCK WASHER SPLIT ZINC PLATED H4 2 1 4 20 HEX NUT GRADE 2 ZINC PLATED ...

Page 17: ...SQUARE NECK BOLT GRADE 2 ZINC PLATED H7 4 5 16 ID X 0 88 OD FLAT WASHER USS ZINC PLATED H8 12 5 16 ID X 0 69 OD FLAT WASHER SAE ZINC PLATED H9 16 5 16 LOCK WASHER SPLIT ZINC PLATED H10 16 5 16 18 HEX NUT GRADE 2 ZINC PLATED H11 5 M6 X 1 X 20MM LONG BUTTON HEAD TORX SCREW BLACK OXIDE H12 2 M6 X 1 X 18MM LONG COUPLING NUT CLASS 8 ZINC PLATED H13 1 M6 X 1MM NO SLIP CLIP ON BARREL NUT ...

Page 18: ... BETA 4 25 2019 H14 2 M5 X 0 8 X 10MM LONG BUTTON HEAD CAP SCREW BLACK OXIDE H15 7 1 4 ID X 0 63 OD FLAT WASHER SAE BLACK OXIDE H16 2 M6 LOCK WASHER SPLIT BLACK OXIDE H17 1 1 1 16 OD X 1 2 ID X 3 8 WIDTH PRESS IN RUBBER GROMMET H18 1 1 FT LONG RUBBER TRIM NARROW U End of Section ...

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 removing screws remove five 5 accompanying body clips on top of rear fender and two 2 on corner trim CAUTION Use care removing body clips and corner trim corner trim has a hidden clip on backside All items...

Page 20: ...r near inside of 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 Passenger Rear Fender Removal fender resting on tire Air Tank shown installed T15 Screw FRONT Brake Light Wiring Still Connected ...

Page 21: ...tion 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 rear deck as shown below Do not discard large bolt as it will be re used Smaller bolt i e front bolt will be replaced Figure 6 Air Tank Bracket Mounting Locations side view Figure 7 Air Tank Bracket Mounting Locations top view FRONT Front Bolt FRONT Rear Deck bolt Front Deck b...

Page 22: ...till 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 clearance to coil spring Figure 8 Front Air Tank Bracket stops at corner Gusset Shown with Air Tank Figure 9 Installing Front Air Tank Brackets Exploded View FRONT Bracket butts up to Frame Gusset FRONT ...

Page 23: ...e then 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 correctly installed inside Tube as shown below NOTE To hold Coupling Nut while tightening screw use an SAE standard 10mm open end wrench Figure 11 Installing Rear Air Tank Bracket Proper Bolt Orientat...

Page 24: ...ey 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 proper sized box end wrench adjust as necessary to match fitting orientation shown in figure below 8 5 5 Connect a minimum of 6 FT of supplied 1 4 Air Tubing to front Air Fitting as shown below Conn...

Page 25: ...e 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 maintain a minimum clearance between suspension spring and Bracket It is ok if Air Tank contacts inner plastic fender or back of Brackets Figure 14 Installing Air Tank onto Brackets Exploded View 8 6 4 Onc...

Page 26: ...ts X3 101 X3 202 and X3 204 2 8 7 2 On Driver side of vehicle remove one bolt holding rear deck as shown below M6 bolt and nut i e front bolt will be replaced and may be discarded Figure 15 Air Compressor Bracket Mounting Locations side view Figure 16 Air Compressor Bracket Mounting Locations top view FRONT Front Bolt FRONT Chassis Tube Front Deck bolt ...

Page 27: ...nal torque all bolts NOTE Ensure forward edge of clamp is butted against weld bead on chassis which increases clearance between back of X3 101 and springs There should be a minimum clearance to coil spring Figure 17 Front Air Compressor Bracket stops at corner Gusset Shown with Air Compressor Figure 18 Installing Air Compressor Bracket Exploded View FRONT Bracket butts up to Frame Gusset FRONT X3 ...

Page 28: ...d cause harm or injury Figure 19 Air Tubing Route from Air Compressor to Air Tank 8 8 2 On a bench install Air Compressor Leader Hose Adapter Bracket X3 102 on to back of Compressor and zip tie hose as shown below Use a razor blade or scissors to cut Rubber Grommet in half Apply adequate Kleinn Air Horn Juice to end of Leader Hose when installing Air Fitting F8 CAUTION It is not recommended to att...

Page 29: ...end Figure 21 Installing Air Compressor onto Bracket Exploded View 8 8 4 Install Air Compressor Air Filter onto end of Compressor per included directions in Compressor package NOTE if desired select a dry location with less exposure to dust water and mud then route remote Air Compressor Filter and connect to end of Compressor Figure 22 Air Compressor Filter Remote Tubing shown attached example veh...

Page 30: ... 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 necessary as space constraints near Sway Bar make it difficult to insert bolts with Bracket in place Apply tape long enough that it can be easily removed after installation Figure 24 Carriage Bolts t...

Page 31: ...ugated 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 9 6 Install X3 301 by pulling upwards on Brake Lines and sliding Bracket underneath but above Coolant Tubes as shown below Use supplied Zip ties and gently secure Brake Lines Coolant Tubing and Wiring to Bracket using smal...

Page 32: ...mpet 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 to Bracket Figure 28 Installing Trumpet Support Clamp and Trumpets Exploded View H9 2 H10 2 H8 2 X3 302 H5 2 LONG SHORT ...

Page 33: ... as desired NOTE It may be necessary to reconnect Trumpets to Air Horn Driver before installing hardware Figure 29 Installing Air Horn Driver with Tubing attached Exploded View 8 9 9 With Trumpets and Air Horn Driver connected final torque all fasteners as shown per order below NOTE position slide X3 301 Bracket as necessary to ensure maximum clearance around springs Figure 30 Final tightening of ...

Page 34: ... pictures Figure 31 Final installation of 102 Air Horn X3 Turbo R shown 8 10 Connect Remote Quick Connect Kit to Vehicle 8 10 1 Route and attach Quick Connect Coupler Kit to vehicle as desired using attachment bracket and self drilling fasteners supplied in Coupler package 8 10 2 Use supplied 1 4 tubing and attach to port shown in Figure 12 above Some example locations include under rear deck near...

Page 35: ...9 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 Fuse Diagram for Air Horn System Figure 33 Suggested Ignition Relay Diagram for Air Horn System ...

Page 36: ...1 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 s and fuse s Shown below is an example location on rear firewall behind Passenger seat next to battery Use supplied self tapping screws as necessary Figure 35 Relay and Fuse location example behind...

Page 37: ...are 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 36 Recommended install location for Air Horn Button 9 5 2 If desired otherwise find another suitable location that has 1 of clearance behind for terminals then mark location for drilling Drill a 3 4 ho...

Page 38: ...astened 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 neighbors or others in vicinity WARNING NEVER operate train horns with ears close to trumpets or in an enclosed space without substantial hearing protection i e Ear Plugs and Ear Muffs for all per...

Page 39: ...ecommended 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 fasteners have not moved 12 2 Yearly or every 12000 miles inspect OE wiring tubing cables etc where Kit parts may touch to verify no abrasion or rubbing 12 3 Yearly or every 12000 miles remove all road...

Page 40: ...ranty Information Thank you for purchasing this X3 KIT Shall you experience any unexpected problems during installation or have problems with any part at any time please contact Kleinn support Kleinn Air Horns 2019 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web www Kleinn com ...

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