Kleinn JEEPKIT-1 User manual

Bolt-
on Air Horn & Compressor Kit for Jeep Wrangler JK
SAVE THIS MANUAL FOR FUTURE REFERENCE
It is essential that y
operator of this product read and
understand the contents of this manual
before installing and using this product.
odel JEEPKIT-1
on Air Horn & Compressor Kit for Jeep Wrangler JK
SAVE THIS MANUAL FOR FUTURE REFERENCE
USER ANUAL
I PORTANT:
It is essential that y
ou and any other
operator of this product read and
understand the contents of this manual
before installing and using this product.
on Air Horn & Compressor Kit for Jeep Wrangler JK

 odel JEEPKIT-1
Components:
1 2.5 Liter, 4-port air tan
1 Model 6250RC compressor
1 Dual trumpet air horn
1 Installation wiring & connector it
1 Compressor installation hardware (Pac age #1 - inside compressor box)
1 JEEPKIT mounting hardware (Pac age #2)
1 Compressor/Tan mounting brac et
1 Horn mounting brac et
1 12’ length air tubing
PARTS PACKAGES
Package #1 – Compressor Installation Hardware
Qty 4 13/64” Nuts, bolts, washers & loc ing washers
(Compressor mounting hardware)
Qty 1 Remote Mount Air Filter Assembly
Qty 1 Remote mount air filter fitting for air filter connection
Qty 1 Replacement air filters
Qty 1 Leader Hose Brac et Clip
Qty 1 Air line for remote mounting air filter

Package #2 – Jeep Kit bracket and tank hardware
Qty 6 5” bolts
Qty 6 Nyloc nuts
Qty 3 Rear mount plates
Qty 4 Nuts, bolts, and washers – (Air tan mounting hardware)
Compressor/Tank – General Information
Your Jeep Kit comes complete with a model 6250RC, 9% duty cycle compressor and a 2.5 liter
air tan . Please follow the installation instructions that follow in order to enjoy the best use of
your air horn it.
CAUTION - To reduce ris of electrical shoc or electrocution:
• Do not disassemble the compressor. Do not attempt repairs or modifications. Refer to
qualified service agencies for all service and repairs.
• Do not use this product in an area where it can fall or be pulled into water or liquids.
• Do not reach for this product if it has fallen into liquid.
• Use this compressor with 12-volt DC systems only.
• This product should never be left unattended during use.
IMPORTANT:
• Tan is rated for 120 PSI maximum wor ing pressure.
• Tan is not to be used as a breathing device.
• Bleed pressure from tan before servicing or adding attachments.
• Use only attachments or tools rated for 120 PSI wor ing pressure or less.
• Apply sealant or Teflon tape to threads of fittings prior to assembly and tighten each part
with a wrench.
• Do not over tighten, since brass threads can be stripped.
• Always release air from tan before servicing.
• To remove accumulated condensation inside the tan , disconnect power from the compressor
and release the pressurized air by sounding the horns. Unbolt the air tan , then drain water
by removing the drain plug at the bottom of the tan . Once the water is drained, replace the
plug and re-mount the tan . Use Teflon thread tape to ensure a good seal.
CAUTION:
DO NOT PRESSURIZE YOUR TANK UNTIL YOU HAVE INSTALLED ALL
NECESSARY PORT FITTINGS AND ACCESSORIES.
FAILURE TO DRAIN TANK AND RE OVE CONDENSATION WILL CAUSE TANK
TO RUST PRE ATURELY.RUSTED TANKS CAN FAIL CAUSING EXPLOSIONS OR
FATAL INJURIES. DISCARD TANK I EDIATELY IF IT IS RUSTED.

Compressor/Tank Installation
Included in your it is a vehicle-specific mounting brac et for the compressor and air tan . The
brac et clamps around the horizontal beam located above the rear differential.
Preparation
1. Locate the horizontal beam above the rear differential. There is a small wiring harness,
attached to the top of the support with two plastic clips. Remove the clips to allow free
movement of the wiring harness. It is not necessary to salvage the clips – they will not
be re-used (see photo 1).
2. Attach the compressor to the vehicle-specific mounting brac et using the bolts in
Pac age 2. The compressor should be mounted with the piston on the driver’s side of
the vehicle, facing away from the tan mounting location. Bring the bolts up through the
bottom of the mounting plate and have the nuts on the top. Do not mount the tank yet.
3. Insert two 5” mounting bolts into each rear mount plate (see photo 2).
Photo 1 – Horizontal beam with wiring harness clips
removed
Photo 2 – Rear Mount Plates with bolts inserted
Mounting the compressor/tan brac et
1. Wor from the driver’s side of the vehicle and slide all three rear mount plate/mounting
bolt sub-assemblies onto the horizontal beam. The rear mount plates should be towards
the rear of the vehicle, the bolts should be extending over and below the beam, pointing
toward the front of the vehicle (see photo 3). As each sub-assembly is positioned over
the beam, slide it towards the passenger side of the vehicle so that the three sub-
assemblies are spaced at roughly the same intervals as the three sets of mounting holes on
the brac et (see photo 4). Ma e sure the wiring harness you detached from the beam
earlier is lying on TOP of the bolts and not running under the bolts! Helpful Tip: Using
electrical tape to temporarily hold the bolts on the rear mount plates will make this task
easier.

Photo 3 – Slide the rear mount plate/bolt assemblies
over the beam. Wor from the driver’s side and slide
the assemblies towards the passenger’s side
Photo 4 – All three rear mount plate/bolt assemblies in
place.
2. Position the brac et in front of the beam, then align the rear mount/bolt assemblies so that
the bolts pass through the mounting holes in the brac et. Hand tighten the six Nyloc nuts
onto the bolts.
3. Position the entire brac et assembly towards the passenger side of the beam. There is a
welded joint at the end of the beam – the brac et should be butted up against that weld.
Do not try to attach the bracket over the weld (see photos 5 & 6)
4. Using an 11mm gear wrench or a ratchet with a 6” extension, tighten the six Nyloc nuts.
Alternate between top and bottom so that the rear mount plates sit flush against the bac
of the beam and the bolts sit flush on the top and bottom of the beam. Use a wrench to
hold the bolt heads while tightening.
5. Attach a short section (approx 12-18”) of the blac tubing in the compressor accessory
pac age to the air inta e on the front of the compressor. Route the other end into the
existing opening in the floor brace just above the compressor.
Photo 5 – Compressor on mounting brac et, as seen
from the front of the vehicle.
Photo 6 – Mounting brac et, as seen from underneath.

Ma ing the air connections
1. Temporarily slip the emergency bra e cables out of their support to allow room for
installing the air tan . Position the air tan on top of the mounting brac et with the
fittings facing the driver’s side of the vehicle and the compressor. Do not attach the tan
to the brac et yet (see photo 7).
2. Remove the red rubber plug from the end of the steel braided leader hose on the
compressor and apply Teflon thread tape to the threads on the chec valve at the end of
the leader hose.
3. Ma e a loop with the leader hose and position the hose between the compressor body and
the bac of the brac et (see photo 8).
4. Thread the leader hose into the tan and tighten with a wrench. It is important that the
connection is snug, but not over tightened. When the brass female adapter on the tan
starts turning, you’ve tightened the leader hose enough.
5. Connect the air tube to the compression fitting on the tan . For best results, ma e sure the
end of the tube is cut clean and square. Route the tube over the top of the brac et that
holds the Jeep EVAP canister.
Photo 7 – Emergency bra e cable support Photo 8 – Air tan positioned on mounting brac et.
Note how the braided steel leader hose is looped
between the compressor body and the mounting brac et.
Mounting the air horn
1. Locate the EVAP canister under the vehicle. It is towards the driver’s side, just forward
of the rear axle (see photo 9).
2. Remove the two 5/8” bolts for the EVAP canister mounting brac et.
3. Use the mounting bolts found inside the horn box to attach the horns to the horn
mounting brac et
4. Cut your tubing to length, ma ing sure the end is clean and square. Connect the air line
to the solenoid valve, then slip the horn mounting brac et UNDER the EVAP canister
brac et and align the holes. Re-install the 5/8” bolts through the EVAP canister mount
and the horn brac et (see photo 10)

Photo 9 – EVAP canister. Note the two 5/8” mounting
bolts
Photo 10 – Air horn brac et mounted under EVAP unit
brac et
Pre-wiring
1. Disconnect ground cable from vehicle’s battery.
2. Ground the compressor blac wire. The nut that secures the emergency bra e cable
support just forward and above the rear differential is a good grounding point.
3. Your wiring it includes red, yellow, purple and blac wires that will need to be run the
length of the vehicle. Run the red and yellow wires from the battery area (passenger
side), across the engine compartment, and bac to the compressor/tan .
4. Run the blac and purple wires to the bac from the area of the ignition switch harness
(under the steering column). The blac wire will terminate at the air horns, the purple
wire will run all the way bac to the compressor/tan .
Be sure to keep your wiring away from heat sources such as the exhaust!
Wiring Connections
1. Use the relay including in your wiring pac age to supply power to the compressor.
Mount the relay near the battery and wire as follows:

• Pin 30 – to the 10 gauge red wire that runs the length of the vehicle and attaches to
the red wire on the compressor
• Pin 85 – to the yellow wire runs the length of the vehicle to one side of the pressure
switch (it does not matter which terminal)*
• Pin 86 – to ground
• Pin 87 – to one end of the fuse holder (cut the loop)
* before attaching spade connectors to the ends of the wires that connect to the
pressure switch, pass the wires through the opening in the black rubber pressure
switch cover. Slide the cover over the pressure switch once the connections have
been completed.
2. Connect the end of the purple wire at the compressor/tan to the open terminal on the
pressure switch. Connect the other end of the purple wire to the 12v+ ignition wire in the
ignition switch harness.
3. The blac wire will be your horn trigger. If you want to activate your horn using the
pushbutton supplied with the it, connect one side of the pushbutton to ground and the
other side of the pushbutton to the blac wire. If you want to use your factory horn
switch instead of the pushbutton, connect the blac wire to the vehicle (-) horn wire,
located in the ignition switch harness. In either scenario, the other end of the blac wire
should be connected to one of the wires (it doesn’t matter which) coming out of the
solenoid valve on the air horn.
4. Use a leftover section of your blac wire to connect the remaining wire on the air horn
solenoid valve to +12v ignition. You can use the +12v ignition you already have
running to the bac of the vehicle via the purple wire.
5. Connect the remaining end of the fuse holder to the + terminal of the battery or the
‘power point’ on the corner of the fuse box, in front of the battery.
6. Insert the fuse in the fuse holder to complete your wiring
7. Use the wire loom supplied with the it to protect your wiring!
8. Use the supplied wire ties to secure the factory wiring harness that was detached earlier
to the holes on the compressor mounting brac et.
Mounting the air tan
1. After all electrical connections have been completed, pressure test the tan before bolting
it to the brac et. To pressure test the tan , complete your wiring and turn on the ignition
to run the compressor. Once the pressure switch shuts the compressor off, spray soapy
water on all the air connections at the tan . If you see bubbles, tighten the connection
slightly or add more Teflon tape.
2. Once you have pressure tested the system, the tan can be mounted to the brac et. Use
the four nuts, bolts and washers included in hardware pac age #1. Install the bolts from
the top downward. Helpful Tip: The passenger side rear bolt will be difficult to access.
Use a piece of electrical tape to temporarily hold the bolt into the tank s foot when doing
your final positioning of the tank on the bracket.

CO PRESSOR OPERATING INSTRUCTIONS
I PORTANT: The compressor has a maximum wor ing pressure of 120 PSI and is capable of
9% duty cycle. It is designed for use with air horns, air bags and other accessories that utilize the
compressed air stored in the tan . Always operate the compressor at or below the MAXIMUM
PRESSURE RATING of the compressor. Operation exceeding maximum pressure ratings and or
duty cycle will result in damage to air compressor.
1. Your air compressor is equipped with an AUTOMATIC THERMAL OVERLOAD
PROTECTOR. This feature is designed to protect the air compressor from overheating and
causing permanent damage to your air compressor. The thermal overload protector will
automatically cut off power to your air compressor should the internal operating temperature
of the air compressor rise above safe levels during excessive use.
2. Should your air compressor automatically shut off while in use; do not attempt to restart the
air compressor. Turn power switch to the air compressor to the OFF position. The automatic
thermal overload protector will automatically reset when internal temperature of the air
compressor drops below safe level. After allowing air compressor to cool off for about 30
minutes, you can safely resume use of the air compressor by turning on the air compressor.
3. To prevent discharge of your vehicle’s battery and to provide pea performance, we strongly
recommend that you eep the vehicle’s engine running while using the air compressor.
4. ONLY OPERATE THE AIR COMPRESSOR IN WELL-VENTILATED AREAS.
Compressor Maintenance & Repairs
1. Periodically chec all electrical and fitting connections. Clean and tighten as needed.
2. Periodically chec all mounting screws. Tighten as needed.
3. Replace air filter element periodically. Replacement frequency depends on operating
frequency and operating environment. For frequent use in dusty environment, you should
replace air filter element more often.
4. Regularly clean dust and dirt from compressor.
5. Your air compressor is equipped with permanently lubricated, maintenance free motor.
Never lubricate compressor.
6. Repairs should be performed by Manufacturer or Manufacturer’s Authorized Service
Agencies only.
CAUTION: Never touch the air compressor or fittings connected to the air compressor with bare
hands during or immediately after use. Leader hose and fittings will become very HOT during
and after use.


Kleinn odel
Kleinn Automotive Accessories
LI ITED WARRANTY
Kleinn Automotive Air Horns warrants this
product, when properly installed and under
normal conditions of use, to be free from
defects in wor manship and materials for a
period of one year from provided date of
purchase. To receive a replacement or for
rep
airs, return the complete unit to retailer from
whom it was purchased along with proof of
purchase.
Returns should be made within the time period
and conditions of the retailer’s policy for
exchanges. If you are unable to contact your
dealer, contact Kl
replacement at our option.
Kleinn odel
JEEPKIT-1
Kleinn Automotive Accessories
P.2094 N. Dragoon St
Tucson, AZ 85 45
Phone: [phone]
Fax: [phone]
[e-mail]
LI ITED WARRANTY
Kleinn Automotive Air Horns warrants this
product, when properly installed and under
normal conditions of use, to be free from
defects in wor manship and materials for a
period of one year from provided date of
purchase. To receive a replacement or for
airs, return the complete unit to retailer from
whom it was purchased along with proof of
purchase.
Returns should be made within the time period
and conditions of the retailer’s policy for
exchanges. If you are unable to contact your
dealer, contact Kl
einn directly for repairs or
replacement at our option.