Klenn Air Horns JL-JK-OBA Installation Manual Download Page 3

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JL-JK-OBA

Installation and Operation Manual

PG 3/35

REV: A (1/21/2019)

Table of Contents

LIST OF FIGURES .................................................................................................................................................5

How to Use this Manual .....................................................................................................................................6

2.1. Interactive Manual using Adobe Reader ....................................................................................................6

2.2. Your Kit SKU Number and this Manual .......................................................................................................6

2.3. Illustration/Photo Details and Orientation .................................................................................................6

Safety First ..........................................................................................................................................................7

Application Chart ................................................................................................................................................8

4.1. 100% Direct Bolt-On Vehicle List ................................................................................................................8

4.2. **Excluded Vehicles ...................................................................................................................................8

4.3. Aftermarket Product Compatibility ............................................................................................................8

Installation Overview ..........................................................................................................................................9

5.1. Kit Layout and System Location(s) ..............................................................................................................9

5.2. Approximate Installation Time ................................................................................................................ 10

5.3.

***Quick Install Outline

........................................................................................................................... 10

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

Parts List .......................................................................................................................................................... 12

7.1. Parts List covers following SKU Numbers ................................................................................................ 12

7.2. Pre-Packaged Electro-Mechanical 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 & Special Hardware .................................................................................... 15

7.6. Hardware/Fasteners ................................................................................................................................ 16

On-Vehicle Electrical Installation ..................................................................................................................... 18

8.1. Relay and Fuse Diagram for Air Compressor and Air Tank Pressure Switch ........................................... 18

8.2. Suggested Wire Routing for Air Compressor and Air Tank Pressure Switch ........................................... 19

8.3. Disconnect Vehicle Battery(s) .................................................................................................................. 19

8.4. Connect Wiring to Relay(s) and Fuse(s), then Attach to Vehicle ............................................................. 19

8.5. Route Wiring ............................................................................................................................................ 20

Bench Assembly Steps ..................................................................................................................................... 21

Summary of Contents for JL-JK-OBA

Page 2: ...stallation and Operation Manual Go to Table of Contents PG 2 35 REV A 1 21 2019 This digital PDF is interactive Please save ink and paper Open interactive manual using Adobe Reader on PC MAC and all s...

Page 3: ...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 Parts List covers following SKU Num...

Page 4: ...JL ONLY Adapter Bracket JL 204 to Frame Installation 28 10 3 JL ONLY Air Tank Bracket JK 201 to Frame Installation 29 10 4 Air Tank to Tank Bracket Installation 32 10 5 Skid Plate and Compressor Insta...

Page 5: ...p with Rubber Trim 24 Figure 9 JK 201 to Evap Canister Install 25 Figure 10 JK 201 to JKU Mounting Points for Hardware 26 Figure 11 JK 201 JK 203 Mounting Strap Install over Crossmember 27 Figure 12 J...

Page 6: ...U Number and this Manual This manual covers installation testing and operation of following SKU part numbers 2 2 1 JL JK OBA i e On Board Air System 2 2 2 JK6450 i e Dual Compressor Upgrade NOTE Illus...

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

Page 8: ...switches based on preference of installed switch locations and wire grounding points 4 2 Excluded Vehicles JL JK OBA is NOT compatible with following JEEP vehicles 4 2 1 ALL 2 Door Jeep JL 4 2 2 ALL...

Page 9: ...TING LOCATION APPROX INSTALL TIME 1 3 Gal Air Tank Under vehicle in between driveshaft exhaust JKU in front of Evap Canister 2 Hours 2 6450RC Air Compressor Dual Air Compressor with JK6450 Upgrade Kit...

Page 10: ...t is estimated to take 3 5 Hours 5 3 Quick Install Outline For person s with experience installing Kleinn bolt on kits JL JK OBA can be installed in an order similar to below 1 Route Wiring install Re...

Page 11: ...tility Knife or Utility Razor blade 6 1 9 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 elect...

Page 12: ...leinn support if any questions arise 7 1 3 Review pre packaged items i e train horn box air compressor air tank etc 7 1 4 Review Air Fittings and Tubing 7 1 5 Review Wiring and Accessories 7 1 6 Revie...

Page 13: ...on Air Tank 1 4 NPT Drain Valve 4 1 52175 view location on Air Tank 1 4 NPT 175 PSI Safety Valve 5 4 3 50040 view location on Air Tank 3 included in JK6450 1 4 NPT Hex Plug 6 1 51414L view location on...

Page 14: ...Kit with Air Hose and Bag 11 1 KLEINN AIR HORN JUICE Thread Sealant for NPT Fittings 7 4 Electrical Small Components and Related Items ITEM QTY PART NUMBER DESCRIPTION PICTURE 12 1 WIRE KIT Full Wire...

Page 15: ...kets Special Hardware ITEM QTY PART NUMBER DESCRIPTION PICTURE 15 1 JK 101 COMPRESSOR MOUNTING BRACKET SKID PLATE 16 1 JK 201 AIR TANK MOUNTING BRACKET 17 2 JK 202 AIR TANK STRAP 18 1 JK 203 JK FRAME...

Page 16: ...E REAR 1 FOR JKU ONLY 6 SQUARE NECK BOLT GRADE 2 ZINC PLATED 7 16 14 X 1 4 ADAPTER BRACKET 3 MOUNTING STRAP 1 FOR JLU ONLY 7 HEX BOLT GRADE 8 8 ZINC PLATED M6 X 1 X 30 LONG 1 TANK BRACKET TO FRAME 1 F...

Page 17: ...N 125 ZINC PLATED M12 X 24 OD 2 ADAPTER BRACKET TO FRAME 2 FOR JLU ONLY 18 LOCK WASHER SPLIT LOCK ZINC PLATED 1 4 4 TANK STRAPS 4 19 LOCK WASHER SPLIT LOCK ZINC PLATED 3 8 7 SKID PLATE 6 MOUNTING STRA...

Page 18: ...al Installation CAUTION Follow all recommended safety precautions for working on vehicle s electrical system consult vehicle owner s manual for further instruction 8 1 Relay and Fuse Diagram for Air C...

Page 19: ...Disconnect Vehicle Battery s 8 3 1 Use special care if vehicle is equipped with Auxiliary Auto Stop Battery Consult Owner s Manual 8 4 Connect Wiring to Relay s and Fuse s then Attach to Vehicle 8 4...

Page 20: ...8 5 3 Install supplied fuse holder on end of power wire by cutting the loop in fuse holder and connecting supplied Ring terminal to one end and Butt connector to other CAUTION Do not install 30 amp fu...

Page 21: ...asteners clean and dry using proper socket and box end wrench Not including Air fittings 9 1 Air Tank Fittings 9 1 1 Apply two small drops of Kleinn Air Horn Juice to each male pipe thread 9 1 2 Attac...

Page 22: ...der hose facing inward as shown below Figure 3 Compressor Mounted onto JK 101 JK6450 Upgrade Shown Figure 4 Compressor Fasteners Orientation Stack Up 9 2 3 Tighten all fasteners firmly or if accurate...

Page 23: ...ank supports as shown in Figure 5 below NOTE Use a short section of tape to secure rubber if it falls off during installation process Figure 5 Rubber Trim Attached to JK 201 Bracket shown on bench 9 3...

Page 24: ...end up shaped round like tank as shown in Figure 7 below Figure 7 JK 202 Hand Formed Bent around Air Tank 9 3 4 Remove Air Tank from Tank Bracket but leave Air Tank Straps attached with a single bolt...

Page 25: ...sult vehicle owner s manual 10 1 JK ONLY Air Tank Bracket JK 201 to Frame Installation 10 1 1 Locate factory charcoal canister in rear of vehicle directly in front of rear coil springs on driver side...

Page 26: ...igure 10 Hand tighten 10 1 5 Install hardware 4 14 2 20 and 10 into front hole of JK 201 going through crossmember at location B as shown in Figure 10 Ensure bolt is inserted from bottom with nut abov...

Page 27: ...essary final adjustment to position of JK201 Tank Bracket then final tighten all fasteners using below method Figure 11 JK 201 JK 203 Mounting Strap Install over Crossmember 10 1 9 Firmly tighten all...

Page 28: ...2 X 1 5 threaded holes on rear crossmember in front of axle as shown below Figure 12 JLU Rear Crossmember Mounting Locations 10 2 2 Using hardware 8 17 23 install JL 204 as shown in Figure 13 below Ha...

Page 29: ...crossmember as shown circled in Figure 14 below Do NOT discard this nut and use care when removing it to prevent stripping threads or breaking stud Figure 14 JLU Middle Crossmember Ground Strap Mounti...

Page 30: ...nd Operation Manual Go to Table of Contents PG 30 35 REV A 1 21 2019 Figure 16 JK 201 JL 204 Hardware Attached Figure 17 JK 201 JL 204 Section View with Hardware Stack Up JK 201 shown in Green TOP JL...

Page 31: ...tighten Figure 18 Ground Strap Nut removed JK 201 Tank Bracket shown in place 10 3 4 Insert three 3 6 facing downwards through JK 201 and JL 204 at holes A as shown in Figure 15 10 3 5 Secure JK 201 J...

Page 32: ...15 6 Tighten hardware E to 11 13 ft lbs 7 Tighten hardware D to 18 21 ft lbs 8 Tighten QTY 2 M12 bolts connecting JL 204 to rear crossmember to 25 30 ft lbs 9 Tighten QTY 3 square neck bolts A to 18...

Page 33: ...cket Air Tank not shown 10 6 Connect Air Compressor Leader Hose to Air Tank 10 6 1 Apply two small drops of Kleinn Air Horn Juice to male pipe thread on Compressor outlet leader hose and connect to 8...

Page 34: ...verify adequate air pressure is available 11 3 3 Test fill tires on vehicle bicycle etc 11 3 4 Use Air Blow Gun 11 3 5 Use Air Impact Gun 12 General Operation of Kit 12 1 Compressor Operation WARNING...

Page 35: ...tank or air lines which can suddenly release air pressure causing injury to nearby people 13 5 Yearly or every 12000 miles clean or replace air compressor air filter element Replacement frequency dep...

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