Kleinn Air Horns TJXTREME User manual

TJXTREME
INSTALLATION MANUAL
© Kleinn Air Horns 2020, All rights reserved.
PO Box 91278 Tucson, AZ 85752
Phone: [phone]
Web: www.Kleinn.com
REV: A (5/8/2020)

TJXTREME
Installation and Operation Manual
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Installation and Operation Manual
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Table of Contents
1. LIST OF FIGURES..................................................................................................................................................................5
2. 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
3. Safety First ..........................................................................................................................................................................7
4. Application Chart ................................................................................................................................................................8
4.1. Bolt-On Vehicle List ....................................................................................................................................................8
4.2. **Excluded Vehicles...................................................................................................................................................8
4.3. Aftermarket Product Compatibility............................................................................................................................8
5. Installation Overview ..........................................................................................................................................................9
5.1. Kit Layout and System Location(s) .............................................................................................................................9
5.2. Install Process Outline ..............................................................................................................................................11
5.3. Approximate Installation Time.................................................................................................................................11
6. List of Tools and Supplies..................................................................................................................................................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 Electro-Mechanical Kit Items.............................................................................................................13
7.3. Air Fittings and Related Items ..................................................................................................................................14
7.4. Electrical Small Components and Related Items......................................................................................................15
7.5. Bolt-On Mounting Brackets & Special Hardware .....................................................................................................16
7.6. Hardware, Fasteners and Soft Parts.........................................................................................................................16
7.7. Add-On Accessories..................................................................................................................................................18
8. Bench Assembly ................................................................................................................................................................19
8.1. Assemble Air Fittings to Air Tank .............................................................................................................................19
8.2. Assemble Air Compressor to Bracket (TJ-101) .........................................................................................................20
8.3. Disassemble Trumpets from Air Horn Drivers..........................................................................................................21
8.4. Assemble Air Horn Drivers to Bracket (TJ-101) ........................................................................................................21
8.5. Connect Air Compressor Leader Hose......................................................................................................................22
8.6. Connect Air Horn Drivers with Air Tubing ................................................................................................................22
9. On-Vehicle Mechanical Assembly .....................................................................................................................................23

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9.1. Replace Driver Seat Rear Mounting Bolts ................................................................................................................23
9.2. Drill Holes through Rear Passenger Floor.................................................................................................................24
9.3. Install Ribbed Neck Carriage Bolts through Floor.....................................................................................................25
9.4. Install Air Tank Bracket (TJ-201)...............................................................................................................................26
9.5. Install Horn & Compressor Sub-Assembly (TJ-101)..................................................................................................27
9.6. Install Air Tank..........................................................................................................................................................28
9.7. Connect Air Tubing to Air Tank ................................................................................................................................28
9.8. Final Trumpet Installation ........................................................................................................................................29
9.9. Install 1302 Remote Connect Coupler to Vehicle.....................................................................................................29
10. On-Vehicle Electrical Installation ......................................................................................................................................30
10.1. Relay and 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 Horn Button...................................................................................................................................................32
10.6. Connect Pressure Switch..........................................................................................................................................33
10.7. Connect Air Compressor ..........................................................................................................................................33
10.8. Connect Air Horn Solenoid(s)...................................................................................................................................33
10.9. Secure Wiring to Vehicle ..........................................................................................................................................33
11. Final Steps & Testing of Kit................................................................................................................................................34
11.1. Reconnect Vehicle Battery(s) ...................................................................................................................................34
11.2. Test Air Compressor .................................................................................................................................................34
11.3. Test Train Horns .......................................................................................................................................................34
11.4. Test Quick Connect Coupler .....................................................................................................................................34
11.5. Replace Rear Seat & Carpet/Mat .............................................................................................................................34
11.6. Verify Driver Seat Latches ........................................................................................................................................34
12. General Operation of Kit...................................................................................................................................................35
12.1. Compressor Operation.............................................................................................................................................35
12.2. Horn Operation ........................................................................................................................................................35
13. Routine Maintenance........................................................................................................................................................35
14. Warranty Information.......................................................................................................................................................36
End of Table of Contents

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1. LIST OF FIGURES
Figure 1 –Under Vehicle View Showing Kit Layout (1999 Sport with Aftermarket Exhaust Shown) ..........................................9
Figure 2 –Driver View Showing Kit Location –Behind Frame/Body (2004 Sport Shown)...........................................................9
Figure 3 –Under Vehicle of Actual Kit Installed (1999 Sport with Aftermarket Exhaust & TJXTREME Shown) ........................10
Figure 4 –Air Fittings installed on Air Tank (Top Exploded view, as shown resting on bench) .................................................19
Figure 5 –Air Fittings Orientation (Left & Right view, as shown resting on bench) ..................................................................19
Figure 6 –Air Compressor Installation to Bracket, Exploded View (Showing Air Horn Drivers)................................................20
Figure 7 –Removing Trumpets from Air Horn Drivers, Exploded View.....................................................................................21
Figure 8 –Air Horn Drivers Installation to Bracket, Exploded View (Showing Air Compressor)................................................21
Figure 9 –Air Tubing Connections (View Showing Complete Assembly, as if under vehicle) ...................................................22
Figure 10 –Driver’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 Shown Removed)......................................................24
Figure 13 –Rear Underbody Brace (2004 TJ Sport Shown w/o Holes Drilled) ..........................................................................24
Figure 14 –Ribbed Neck Bolt installation (Cross Section of Floor & 1999 TJ Shown w/ Bolts Installed) ..................................25
Figure 15 –Installing Air Tank Bracket, Exploded View.............................................................................................................26
Figure 16 –Installing Horn & Compressor Sub-Assembly, Exploded View (Air Tubing not Shown)..........................................27
Figure 17 –Installing Air Tank onto Bracket (TJ-201), Exploded View (No Air Tubing Shown)..................................................28
Figure 18 –Re-attaching Trumpets, Exploded View (No Air Tubing Shown).............................................................................29
Figure 19 –Example of Air Coupler Mounted to Bumper .........................................................................................................29
Figure 20 –Suggested Ignition Relay Diagram for Air Horn System (Single 220 Horn Shown) .................................................30
Figure 21 –Suggested Wire Routing for Horn, Air Compressor, and Pressure Switch (TJXTREME Shown) ..............................31
Figure 22 –Relay and Fuse location example under hood (1999 Wrangler Sport 4.0L Shown)................................................32
Figure 23 –Horn Button Installed in Dash (Shown in example vehicle) ....................................................................................32
End of Figures

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2. How to Use this Manual
2.1. Interactive Manual using Adobe Reader
It is recommended to open this digital PDF using Adobe Reader ® to take advantage of following key features:
•Hyperlinks (blue underlined text) allow access to additional content via internet; click/tap to activate
oIncludes Installation Figures and “Figure xx”
•Table of Contents page allows easily navigating this manual; click/tap any section line to go to it
•Bookmarks allow quickly navigating to any section; click/tap
•Zoom IN on pictures by pressing “CTRL and +” at same time on PC, or pinch in on smart devices
•Zoom OUT on pictures by pressing “CTRL and -”at same time on PC, or pinch out on smart devices
To install Adobe Reader ®
On PC, or Mac
•visit https://get.adobe.com/reader/otherversions/
On Android, iPhone/iPad, and Windows devices,
•visit https://acrobat.adobe.com/us/en/acrobat/mobile-app.html
2.2. Your Kit 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 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.
Parts list explicitly state kit differences with (BOLD TEXT) inside parenthesis, shown below part number.
2.3. Illustration/Photo Details and Orientation
This manual may use digitally created illustrations, and/or actual photos of example vehicle. These graphics may
not include exact items found on your vehicle (i.e., electrical wiring, fuel lines, body panels, etc.). Illustrations
typically will be missing details and are for clarity to show critical mounting locations and orientation on vehicle.
Throughout manual yellow arrows with text reading “FRONT”, may be present over
illustrations and pictures. These arrows specify direction toward front of vehicle and
provide clarity to how illustration is viewed.
End of Section
FRONT

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3. Safety First
Read manual thoroughly before starting installation of this kit. Verify you have all parts listed and that you
clearly understand this installation procedure. Contact Kleinn technical support for any questions.
Installation of this kit requires moderate mechanical aptitude; seek professional help if you’re not competent
using hand tools in tight uncomfortable spaces, and around 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 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 application.
CAUTION: means damage could occur to vehicle, or kit parts during, or after installation
WARNING: means injury could occur to you or others, including damage to vehicle, or kit parts
DANGER: means serious injury or death could occur to you or others during installation
End of Section

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4. Application Chart
4.1. Bolt-On Vehicle List
TJXTREME is a partial bolt-on aftermarket product for Jeep vehicles listed in below chart; every effort has been
made to verify correct fitment on these vehicles in their factory, non-modified conditions.
MODEL YR
MODEL
DRIVE
ENGINE
BODY
TRIM
1997-2006
WRANGLER
ALL
ALL
ALL
ALL**
2004-2006
WRANGLER
UNLIMITED
ALL
ALL
ALL
ALL**
NOTE: All vehicles listed require drilling holes through floor and may require drilling holes for ground wires
and installing switches, based on preference of installed switch locations and wire grounding points.
4.2. **Excluded Vehicles
4.2.1. All Rubicon trim packages require relocation of original Air Locker Compressor and Solenoids mounted
above Transfer-Case Skid Plate. Contact Kleinn Sales to purchase optional relocation kit. If preferred,
review following Jeep TJ forum hyperlink for instructions 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 from leading manufacturers:
•Most aftermarket suspension systems that use original upper control arms/links
•Winches, custom front and rear bumpers
4.3.2. This kit has NOT been designed to be compatible with any of the following products:
•Exhaust systems or high-performance intake systems, including super/turbo chargers
•Suspension systems with multiple shocks per wheel, frame modifications, or oversized upper arms/links
•High performance Transfer Cases, Splitters, or Underdrive/Overdrive add-ons, or oversized driveshafts
•Underbody skid plates, high performance transfer case skid plates, or rocker panel protection that
obstructs access to seat bolts
NOTE: Review this manual in full before unpacking items and verify correct space and mounting locations
exist with your aftermarket product(s). To install this kit alongside your other aftermarket product(s),
modification to included parts, your vehicle, or aftermarket product(s) may be required.
End of Section

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5. Installation Overview
5.1. Kit Layout and System Location(s)
TJXTREME consists of following components, located on vehicle, as follows:
ITEM
DESCRIPTION
VEHICLE LOCATION
MOUNTING
METHOD
APPROX.
INSTALL TIME
1
6450RC Air Compressor
Underbody, Driver 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
1-2 Hours
3
220 Series Dual Horn
with Air Solenoids
Underbody, Driver Side
(behind Air Tank, below floor)
Bracket bolts through
rear floor & cross brace
1-2 Hours
Figure 1 –Under Vehicle View Showing Kit Layout (1999 Sport with Aftermarket Exhaust Shown)
Figure 2 –Driver View Showing Kit Location –Behind Frame/Body (2004 Sport Shown)
1
3
FRONT

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Figure 3 –Under Vehicle of Actual Kit Installed (1999 Sport with Aftermarket Exhaust & TJXTREME Shown)
FRONT
FRONT

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5.2. Install Process Outline
For person(s) with prior experience installing TJXTREME, a reminder of install steps are listed below:
UNPACKAGE KIT (SECTION 7)
1. Layout and organize all parts on bench
BENCH ASSEMBLY (SECTION 8)
2. Assemble Air Fittings to Air Tank
3. Assemble Air Compressor to Bracket (TJ-101)
4. Connect Air Compressor Leader Hose Extension Tubing and secure to Bracket (TJ-101)
5. Remove Air Horn Trumpets and assemble Air Horn Drivers to Bracket (TJ-101)
6. Connect Air Horn Drivers with Air Tubing
ON-VEHICLE, MECHANICAL (SECTION 9)
7. Remove Rear Passenger Seat, Carpet/Mat and Drill 2X holes through floor using Guide (TJ-001)
8. Replace Driver Seat Rear Mounting Bolts (X2)
9. Install 2X Ribbed Neck Bolts through Floor; loosely attach 2X Flange Lock Nuts
10. Install 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-201) to vehicle
13. Install Air Tank onto Bracket (TJ-201)
14. Connect Air Tubing to Air Tank
15. Install Trumpets onto Air Horn Drivers
16. Install Quick Connect Coupler in desired location and connect Air Tubing
ON-VEHICLE, ELECTRICAL (SECTION 10)
17. Install Relay & Fuse, route Wiring, and install Horn Button
FINAL STEPS (SECTION 11)
18. Test system and adjust, as needed
19. Replace Rear Passenger Seat and Carpet/Mat
20. Verify Driver Seat latches properly ***if necessary, slightly grind top of inboard bolt for clearance
5.3. Approximate Installation Time
TJXTREME is a multi-faceted product consisting of mechanical, electrical, and pneumatic components.
For a typical home mechanic, auto enthusiast, or technician installing this kit for first time, a professional
installation job with setup and testing of final product, is estimated to take:
•4-8 Hours
End of Section

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6. List of Tools and Supplies
6.1. Standard Tool List (Required)
6.1.1. Basic mechanic’s 3/8” drive socket sets with extensions
•Inch Size Sockets (1/4” – 1” Hex)
•Metric Size Sockets (6mm –20mm Hex)
6.1.2. Basic mechanic’s combination wrenches (box/open-end)
•Inch Size Wrenches (1/4” – 1” Hex)
•Metric Size Wrenches (6mm –20mm Hex)
6.1.3. Basic mechanic’s screwdriver set (Philips, Flat Head)
6.1.4. Torx driver, or socket set (T30-T50)
6.1.5. Diagonal Cutter/Wire Cutter Pliers
6.1.6. Wire Strippers
6.1.7. Wire Terminal Crimpers
6.1.8. Slip-Joint Pliers
6.1.9. Vise Grips, or Locking Pliers
6.1.10. Utility Knife, or Utility Razor blade
6.1.11. Magnetic retrieval tool
6.2. Special Tool List (Recommended)
6.2.1. Power Drill. Right-angle drill (close quarters) beneficial
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. torque wrench
6.2.6. Multi-Meter for 12V DC electrical systems, or equivalent
6.2.7. 12V DC Test Light, or equivalent
6.2.8. Trim Panel Tool, for removing wiring and body clips, when needed
6.3. Shop Consumables List (Recommended)
6.3.1. Quality Electrical tape
6.3.2. Di-electric grease for electrical connections
6.3.3. Heat Shrink tubing for electrical connections
6.3.4. Medium-Strength ThreadLocker (i.e., Blue Loctite® PN 242), or equivalent
6.3.5. Low-Strength ThreadLocker (i.e., Purple Loctite® PN 222), or equivalent
6.3.6. Black/Clear Silicone for drilling holes in body
6.3.7. Sand Paper, or Wire Brushes for installing ground wires
6.3.8. Extra plastic zip ties > 6” long
6.3.9. Extra NPT sealant (i.e., Kleinn Air Horn Juice, Teflon tape, etc.)
6.3.10. Touch-up paint for frame/chassis/body
6.3.11. Typical cleanup supplies
End of Section

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7. Parts List
7.1. Before Starting, Review Parts List
Unpackage and organize Kit across a large work area and verify all parts are included, as listed below.
Contact Kleinn support if any questions arise.
7.1.1. Review pre-packaged Kit items (i.e., K1, K2, etc.)
7.1.2. Review Air Fittings and Tubing (i.e., F1, 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
1
6450RC
6450RC AIR COMPRESSOR KIT –
INCLUDES HARDWARE, REMOTE
AIR FILTER, AIR TUBING,
FITTINGS, EXTRA FILTER
K2
1
6275RT
AIR TANK, 6” OD, 1.5 GAL., 5-
PORT
K3
1
220
220 SERIES AIR HORN KIT –
INCLUDES DUAL SOLENOIDS,
HARDWARE, AIR TUBING, TEE
FITTING

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7.3. Air Fittings and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
F1
1
2151
(view location on Air
Tank)
1/4" NPT PRESSURE SWITCH, 110-
150 PSI
F2
1
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" NPT FEMALE, 90
DEG. ELBOW
F5
1
52835
(view location on Air
Tank)
1/4" NPT DRAIN VALVE
F6
1
54440
(view location on Air
Tank)
1/4" NPT "T" MANIFOLD, FEMALE
F7
1
***
51414
(view location on Air
Tank)
1/4" NPT X 1/4" TUBE FITTING,
MALE STRAIGHT
***INCLUDED INSIDE 1302

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ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
F8
1
51414F
1/4" NPT X 1/4" TUBE FITTING,
FEMALE STRAIGHT
F9
1
25014-1
1/4" 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 WIRE KIT, WITH ELECTRICAL
CONNECTORS AND ZIPTIES
E2
1
LOOM PACK
1/8" X 10 FT WIRE LOOM,
CORRUGATED AND SPLIT
1/4” X 20 FT WIRE LOOM,
CORRUGATED AND SPLIT
E3
1
320
TERMINATOR –NICKEL PLATED
REMOTE HORN BUTTON

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7.5. Bolt-On Mounting Brackets & Special Hardware
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
M1
1
TJ-001
COMPRESSOR BRACKET, DRILL
GUIDE, CUT
M2
1
TJ-101
COMPRESSOR & HORN BRACKET,
CUT, FORMED & WELDED
M3
1
TJ-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
7/16"-20 X 1.75"
HEX BOLT, PARTIALLY
THREADED, GRADE 8, ZINC-
PLATED
H2
1
7/16" X .922" OD
FLAT WASHER, GRADE 8, ZINC-
PLATED
H3
1
7/16"-20
FLANGE LOCK NUT, GRADE 2,
ZINC-PLATED
H4
1
M8-1.25 X 50
HEX BOLT, FULLY THREADED,
GRADE 10.9, PLAIN FINISH
H5
1
M8 X 16 OD
FLAT WASHER, DIN 125, CLASS
8.8, ZINC-PLATED

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ITEM
QTY.
PART
NUMBER/SIZE
DESCRIPTION
PICTURE
H6
1
M8-1.25
FLANGE LOCK NUT, CLASS 8,
ZINC-PLATED
***USE ONLY WITH ITEM H4
H7
2
5/16"-18 X 1.5"
LONG
RIBBED NECK CARRIAGE 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, USS, ZINC-
PLATED
H11
11
5/16"
LOCK WASHER, SPLIT, ZINC-
PLATED
H12
11
5/16"-18
HEX NUT, GRADE 2, ZINC-
PLATED
H13
4
#10 ID X .69" OD
FLAT WASHER, FENDER, ZINC-
PLATED
H14
1
1/4" ID X 0.63"
OD X 1/4" THICK
PRESS-IN RUBBER GROMMET
H15
1
1 FT. LONG
RUBBER TRIM (NARROW "U")

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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 CONNECT COUPLER/COVER,
TIRE CHUCK, STORAGE BAG
X3
1
59830
DIGITAL TIRE INFLATOR
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8. Bench Assembly
Complete following steps off vehicle to facilitate final installation.
8.1. Assemble Air Fittings to Air Tank
8.1.1. Gather all necessary Air Fittings and Air Tank; ensure all threads on fittings and inside ports are clean.
8.1.2. Apply two small drops of Kleinn Air Horn Juice to each 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 Exploded view, as shown resting on bench)
8.1.4. 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, as shown below.
Figure 5 –Air Fittings Orientation (Left & Right view, as shown resting on bench)
FRONT
DRIVER
To Air Comp.
Approx. 30
deg down
To Air Horn
To Coupler
Level &
Vertical
F2
F3
F5
F7
F6
F3
F1
F4
K2

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8.2. Assemble Air Compressor to Bracket (TJ-101)
8.2.1. Remove Compressor from packaging, included hardware, and air filter.
8.2.2. Pry-open plastic air filter housing and install foam filter inside. If desired, attached fittings for remote
air filter; otherwise 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, as shown below. Recommended
to apply Low-Strength Loctite (i.e., Purple) to threads before installing, then final torque to 20 in-lbs.
Figure 6 –Air Compressor Installation to Bracket, Exploded View (Showing Air Horn Drivers)
Air Filter Housing
Air Tubing w/Fitting
for Remote Mount
Air Filter Remote
Mounting Flange
*FLAT
*BOLT
M1
*NUT
K1
*FLAT
*LOCK
H13