Related Manuals for Kleinn Air Horns JT-OBA
Summary of Contents for Kleinn Air Horns JT-OBA
- Page 1 JT-OBA/220 INSTALLATION MANUAL REV: C (6/25/2021) © Kleinn Air Horns 2021, All Rights Reserved PO Box 91278 Tucson, AZ 85752 Phone: (520) 579-1531 Web: https://www.kleinn.com...
- Page 2 JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL This digital PDF is interactive Please save ink and paper… Open interactive manual using Adobe Reader ® on PC, Mac, and smart devices Go to Table of Contents REV: C (6/25/2021)
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Page 3: Table Of Contents
How to Use This Manual ........................5 Interactive Manual Using Adobe Reader ..................5 Your SKU Number & this Manual ....................5 1.2.1 JT-OBA & JT220 ........................5 Illustration/Photo Details & Orientation ..................5 Safety First ............................6 Application Chart ..........................7 Bolt-On Vehicle List ........................ - Page 4 JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL JT220: Attach Horn Drivers to Horn Bracket (JT-200) ..............19 Attach Relay to Tank Bracket ...................... 20 On-Vehicle Mechanical Assembly ....................... 21 Attach Bracket to Vehicle (JT-100) ....................21 Attach Tank to Bracket (JT-100) ....................23 Attach Zip-Tie Bracket (JT-102) ....................
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Page 5: How To Use This Manual
1.2 Your SKU Number & this Manual This manual covers installation, testing, and operation of following SKU part numbers 1.2.1 JT-OBA & JT220 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 necessary graphics are provided to minimize confusion. -
Page 6: Safety First
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 2 Safety First Read manual thoroughly before starting installation of this kit. Verify that you have all parts listed, and that you clearly understand the installation procedure. Contact Kleinn technical support with any questions. -
Page 7: Application Chart
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 3 Application Chart 3.1 Bolt-On Vehicle List The JT-OBA & JT220 have been designed to work for Jeep Gladiator (JT) 2020 and up models (gas only). MODEL YEAR MODEL DRIVE ENGINE BODY TRIM 2020-2021... -
Page 8: Installation Overview
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 4 Installation Overview 4.1 Kit Layout & System Location(s) JT-OBA & JT220 consist of the following components, located on vehicle as follows: APROX. INSTALL ITEM DESCRIPTION VEHICLE LOCATION MOUNTING METHOD TIME Air compressor Under center of Bolt-on with provided 4 hr. -
Page 9: Install Process Outline
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 4.2 Install Process Outline For person(s) with prior experience installing JT-OBA/JT220, a reminder of the install steps is provided below: UNPACKAGE KIT (SECTION 1. Layout and organize all parts BENCH ASSEMBLY (SECTION 2. Assemble air fittings to air tank 3. -
Page 10: List Of Tools & Supplies
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 5 List of Tools & Supplies 5.1 Standard Tool List (Required) 1. Basic mechanic’s 3/8” drive socket sets with extensions • Inch size sockets • Metric size sockets 2. Basic mechanic’s combination wrenches (box/open-end) •... -
Page 11: Parts List
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 6 Parts List 6.1 Review Parts List Unpackage and organize kit across a large work area and verify all parts are included, as listed below. Contact Kleinn support with any questions. 1. Review pre-packaged kit items (K_) 2. -
Page 12: Pre-Packaged Electromechanical Kit Items
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 6.2 Pre-Packaged Electromechanical Kit Items NOTE Items in this section come in their own packages and may include additional items inside package. ITEM PART NUMBER DESCRIPTION PICTURE Model 6450RC Fully 6450RC Submersible Waterproof Heavy Duty Air Compressor... -
Page 13: Air Fittings & Related Items
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 6.3 Air Fittings & Related Items ITEM PART NUMBER DESCRIPTION PICTURE 50040 Hex Plug, 1/4NPT Safety Valve, 175PSI, 52175 1/4NPT 52835 Drain, 1/4NPT 51414L Comp. Fit. 1/4NPT-1/4 (JT220 only) Elbow Adpt. 1/4NPT-1/4NPTF 51414NPTL Elbow 51414 Comp. -
Page 14: Mounting Brackets & Special Hardware
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 6.5 Mounting Brackets & Special Hardware ITEM PART NUMBER DESCRIPTION PICTURE Tank & Compressor (OBA) JT-100 Bracket JT-101 Tank Strap JT-200 220 Horn Bracket (JT220 Only) RZR-102 1/4" Bolt Spacer JT-102 Zip Tie Bracket... -
Page 15: Hardware, Fasteners, & Soft Parts
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 6.6 Hardware, Fasteners, & Soft Parts ITEM PART NUMBER DESCRIPTION PICTURE 3/8"-16 x 2-3/4" Hex Bolt 3/8" Flat Washer 3/8" Split-Lock Washer M8-1.25 x 25mm Hex Bolt M8 x 24mm Fender Washer M8 Split-Lock Washer 1/4"-20 x 2-1/4"... - Page 16 JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 8” Rubber, Tank Mount (JT220 Only) M12-1.5 x 90mm Hex Bolt (JT220 Only) M12 Flat Washer (JT220 Only) M12 Split-Lock Washer (JT220 Only) M12-1.5 Hex Nut 5/16 x 1-1/4” Fender Washer 1/4" ID Rubber Grommet...
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Page 17: Bench Assembly
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 7 Bench Assembly Complete the following steps off of the vehicle to prepare for final installation. Complete the following steps off of the vehicle to prepare for final installation. When assembling components using bolts, nuts, washers, and lock washers follow the assembly order... -
Page 18: Assemble Rubber To Tank Mounts & Tank Straps
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 7.2 Assemble Rubber to Tank Mounts & Tank Straps 1. Rubber is applied to the tank mounts and tank straps to prevent excessive wear and noise. Apply rubber stripping as shown: Tank Mount Figure 3: Tank Mount Rubber... -
Page 19: Jt220: Disassemble Horn Drivers From Air Horns
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 7.4 JT220: Disassemble Horn Drivers from Air Horns 1. Remove trumpets from drivers and set aside. a. Tightly grasp trumpet with both hands and unscrew counter-clockwise. Trumpet may be very tight. 7.5 JT220: Attach Horn Drivers to Horn Bracket (JT-200) 1. -
Page 20: Attach Relay To Tank Bracket
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 7.6 Attach Relay to Tank Bracket 1. Use the supplied self-tapping screw to attach the relay to the rear of the tank/compressor bracket as shown: Figure 8: Relay Mounting Location END OF SECTION Go to Table of Contents... -
Page 21: On-Vehicle Mechanical Assembly
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 8 On-Vehicle Mechanical Assembly Complete the following steps on-vehicle using a lift, vehicle ramps, or other safe lifting method. DANGER: Follow all manufacturer’s instructions for safely lifting vehicle; reference owner’s manual. 8.1 Attach Bracket to Vehicle (JT-100) 1. - Page 22 JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 3. Use H1, H2, & to secure the back of the bracket to the rear crossmember (2). This must be done before tank is installed. 4. Use H7, H9, H10, H11, H21, & to secure the back of the compressor mounting plate to the front crossmember.
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Page 23: Attach Tank To Bracket (Jt-100)
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 8.2 Attach Tank to Bracket (JT-100) 1. Use the tank straps along with H8, H9, & to attach the tank to the bracket as shown. The shorter-bent end of the tank strap attaches to the top of the tank mount. -
Page 24: Jt220: Attach Horn Bracket (Jt-200)
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 8.4 JT220: Attach Horn Bracket (JT-200) 1. Remove M6 nut and bolt from OEM gas tank splash shield, near Transmission crossmember, as shown circled in Figure 6 below. These bolts will be reused. Figure 11: Splash Shield Mounting Points 2. - Page 25 JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 3. Remove factory gas tank skid plate bolt that attaches to this same crossmember. Insert with washer up through this hole. 4. Secure bracket to crossmember using H18, H19, & H20. 5. Route compressor inlet hose and connect filter.
- Page 26 JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 6. Route air hose and wiring to horns and reassemble trumpets to air horn drivers. END OF SECTION Go to Table of Contents REV: C (6/25/2021)
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Page 27: On-Vehicle Electrical Installation
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 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 & Fuse Diagram for Air Horn System Figure 13: Suggested Ignition Relay Diagram for Air Horn System... -
Page 28: Disconnect Vehicle Battery(S)
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 9.2 Disconnect Vehicle Battery(s) 1. Consult owner’s manual. 9.3 Suggested Air Hose/Wire Routings In general, when routing air hose and wires, keep all runs in common areas as much as possible and branch off as needed. Keep runs away from heat sources and sharp edges as much as possible. Below is one possible routing solution. - Page 29 JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL e. Follow the frame under the driver’s door and route the other end of the hose to the compressor. Use the included 3/8” push-to-connect elbow fitting (F7) at the compressor inlet. g. Use the zip-tie bracket attached in...
- Page 30 JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL g. Route the hose down through the drivers-side rear fender, along the top of the frame (above the exhaust), to the back of the tank. h. Mount the bracket to the bed using the included self- tap screws.
- Page 31 JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL Completed routings: Go to Table of Contents REV: C (6/25/2021)
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Page 32: Connect Wires To Fuse & Relay
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 9.4 Connect Wires to Fuse & Relay 1. Find a suitable location for supplied fuse and relay. Shown below is an example location under the hood, next to the battery, mounted on the firewall. Use supplied self-tapping screws, as necessary. -
Page 33: Connect Pressure Switch
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL 9.6 Connect Pressure Switch 1. Route wiring, as desired, to the air tank and connect to the pressure switch, per wiring diagram. NOTE: Either pressure switch wire can be connected to relay or ignition; they are identical. -
Page 34: Final Steps & Testing
operate train horns outdoors when persons are near 10 Final Steps & Testing vehicle without adequate hearing protection. 10.1 Reconnect Vehicle Battery(s) 4. Briefly activate the horns by pressing the horn CAUTION: Before connecting the vehicle battery(s), verify all button for one (1) second. Repeat three (3) times wiring is properly connected and no shorts exists. -
Page 35: General Operation
JT-OBA/220 Kleinn Air Horns INSTALLATION MANUAL marks across fasteners and mounting parts is 11 General Operation good practice to quickly ensure fasteners have 11.1 Compressor Operation not moved. WARNING: NEVER operate the air compressor above its 2. Yearly, or every 12,000 miles, inspect OE wiring, MAXIMUM PRESSURE RATING (see label on body). -
Page 36: Warranty Information
Kleinn Air Horns INSTALLATION MANUAL 13 Warranty Information Thank you for purchasing JT-OBA/220. Shall you experience any unexpected problems during installation, or have problems with any part at any time please contact Kleinn support. END OF MANUAL © Kleinn Air Horns 2021, All rights reserved.
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