Klenn Air Horns JL220 User manual

JL220
INSTALLATION MANUAL
© Kleinn Air Horns 2019, All rights reserved.
PO Box 91278 Tucson, AZ 85752
Phone: [phone]
Web: www.Kleinn.com
REV: A (1/21/2019)

JL220
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. 100% Direct 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. Approximate Installation Time................................................................................................................ 10
5.3. ***Quick Install Outline........................................................................................................................... 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. Parts List covers following SKU Numbers................................................................................................ 12
7.2. Pre-Packaged Electro-Mechanical Items................................................................................................. 12
7.3. Air Fittings and Related Items ................................................................................................................. 12
7.4. Electrical Small Components and Related Items..................................................................................... 13
7.5. Bolt-On Mounting Brackets & Special Hardware .................................................................................... 13
7.6. Hardware/Fasteners................................................................................................................................ 14
8. On-Vehicle Electrical Installation..................................................................................................................... 15
8.1. Relay and Fuse Diagram for Air Horn, Air Compressor, and Air Tank Pressure Switch........................... 15
8.2. Suggested Wire Routing for Air Horn, Air Compressor, and Pressure Switch......................................... 16
8.3. Disconnect Vehicle Battery(s).................................................................................................................. 16
8.4. Connect Wiring to Relay(s) and Fuse(s), then Attach to Vehicle............................................................. 16
8.5. Route Wiring and Install Horn Button..................................................................................................... 17
8.6. Connect Air Horn Solenoid ...................................................................................................................... 17

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9. Bench Assembly Steps..................................................................................................................................... 18
9.1. Horn Bracket Assembly ........................................................................................................................... 18
9.2. Air Tank Fittings....................................................................................................................................... 20
10. On-Vehicle Mechanical Assembly Steps.......................................................................................................... 20
10.1. Horn Bracket Installation......................................................................................................................... 21
11. Initial Testing of Kit.......................................................................................................................................... 25
11.1. Reconnect Vehicle Battery(s) .................................................................................................................. 25
11.2. Test Train Horns....................................................................................................................................... 25
12. General Operation of Kit ................................................................................................................................. 25
12.1. Compressor Operation ............................................................................................................................ 25
12.2. Horn Operation........................................................................................................................................ 25
13. Routine Maintenance...................................................................................................................................... 25
14. Warranty Information ..................................................................................................................................... 26

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1. LIST OF FIGURES
Figure 1 - Suggested Ignition Relay Diagram for Air Horn System .......................................................................... 15
Figure 2 - Suggested Wire Routing for Horn, Air Compressor, and Pressure Switch.............................................. 16
Figure 3 - Horn Driver Installation onto JL-301 ....................................................................................................... 18
Figure 4 –Rubber Trim shown ziptied to JL-301..................................................................................................... 19
Figure 5 - Air Tank with Fittings Installed (JL-JK-OBA Shown)................................................................................. 20
Figure 6 –OEM Splash Shield Mounting Points ...................................................................................................... 21
Figure 7 - JL-301 Attached to Vehicle...................................................................................................................... 21
Figure 8 - JL-301 Attached to Frame Stud .............................................................................................................. 22
Figure 9 - Factory Gas Tank Skid Plate Bolt ............................................................................................................. 22
Figure 10 - Horn Bracket Crossmember Mounts..................................................................................................... 23
Figure 11 - Horn Assembly Installed w/ Wiring and Air Lines ................................................................................ 23
Figure 12 - Horn Trumpets Installed........................................................................................................................ 24

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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
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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. JL220 (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 this 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.
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

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4. Application Chart
4.1. 100% Direct Bolt-On Vehicle List
JL220 is a 100% direct 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
2018-2019
JLU
ALL
3.6L
4 DOOR
ALL**
NOTE: All vehicles listed 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
JL220 is NOT compatible with following JEEP vehicles:
4.2.1. ALL 2-Door Jeep JL
4.2.2. Jeep JLU with 3.0L Diesel/Hybrid.
4.3. Aftermarket Product Compatibility
This kit has been designed and tested to be compatible with leading manufacturers of aftermarket truck steps,
such as Amp Research Power Steps ® and all OEM standard and optional steps.
This kit has NOT been designed, or tested for use with leading manufacturers of aftermarket exhaust systems.

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5. Installation Overview
5.1. Kit Layout and System Location(s)
JL220 consists of following sub-systems, located on vehicle, as follows:
ITEM
DESCRIPTION
MOUNTING LOCATION
APPROX.
INSTALL TIME
1
220 Series Dual Horn with Air Solenoids
Passenger side frame rail, next to
transmission.
2+ Hours
2
JL-JK-OBA KIT (Previously installed)
N/A
3
JL-JK-OBA KIT (Previously installed)
N/A
Figure A - Bottom View Showing Kit Layout (2018 JLU)
2
FRONT

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5.2. Approximate Installation Time
JL220 is a multi-faceted product consisting of multiple mechanical, electrical, and pneumatic components.
For a typical home mechanic, auto enthusiast, or technician installing a Kleinn Bolt-On kit for first time, a
professional installation job with setup and testing of final product, is estimated to take:
•2-4 Hours
5.3. ***Quick Install Outline
For person(s) with experience installing Kleinn bolt-on kits, JL220 can be installed in an order similar to
below:
1. Route Wiring, install Relay, and install Horn Switch
2. Remove Factory splash shield in front of Gas tank
3. Bolt in horn bracket with horn drivers bolted to bracket.
4. Connect wiring and air lines.
5. Install Trumpets into Horn Drivers.
6. Test System and adjust, as needed

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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. Diagonal Cutter/Wire Cutter Pliers
6.1.5. Wire Strippers
6.1.6. Wire Terminal Crimpers
6.1.7. Slip-Joint Pliers
6.1.8. Utility 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 electrical systems, or equivalent
6.2.4. 12V DC Test Light, or equivalent
6.2.5. Trim Panel Tool, for removing wiring push pins
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. Blue Loctite (i.e., Loctite PN 242), or equivalent
6.3.5. Sand Paper, or Wire Brushes for installing ground wires
6.3.6. Extra plastic zip ties > 6” long
6.3.7. Extra NPT sealant (i.e., Kleinn Air Horn Juice, Teflon tape, etc.)
6.3.8. Touch-up paint for frame/chassis
6.3.9. Typical cleanup supplies

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7. Parts List
7.1. Parts List covers following SKU Numbers
7.1.1. JL220 (i.e., 220 Train Horns)
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.
7.1.2. Review pre-packaged items (i.e., train horn box, air compressor, air tank, etc.)
7.1.3. Review Air Fittings and Tubing
7.1.4. Review Wiring and Accessories
7.1.5. Review Bolt-On Mounting Brackets
7.1.6. Review Hardware/Fasteners
7.2. Pre-Packaged Electro-Mechanical Items
NOTE: Items in this section come in their own packages and may include additional items inside package
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
1
1
220
220 Series Horn Kit, with
included solenoid/valve,
and 1/4” Air Tubing, 20
ft. long
7.3. Air Fittings and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
2
1
51414L
(view location on Air Tank)
1/4” NPT X 1/4”
Compression Fitting, 90
Deg Elbow
3
1
25014
1/4” Air Tubing, 10 ft.
long

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4
1
KLEINN AIR HORN JUICE
Thread Sealant for NPT
Fittings
7.4. Electrical Small Components and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
5
1
320
Terminator –Nickel
Plated Remote Horn
Button
6
1
WIRE KIT
Full Wire Kit, with
electrical connectors and
zip ties
7
1
1/8” WIRE LOOM, 10 ft. Long
1/8” wire loom for
electrical routing
7.5. Bolt-On Mounting Brackets & Special Hardware
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
8
1
JL-301
HORN MOUNTING
BRACKET

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7.6. Hardware/Fasteners
ITEM
NO.
PART TYPE
PART SIZE
QTY.
WHERE USED
1
HEX NUT, GRADE 2, ZINC-
PLATED
5/16"-18
4
HORN (4)
2
LOCK WASHER, SPLIT LOCK,
ZINC-PLATED
5/16"
4
HORN (4)
3
FLAT WASHER, SAE, ZINC-
PLATED
5/16" ID X 0.69
OD
4
HORN (4)
4
FLAT WASHER, METRIC DIN
125, ZINC-PLATED
M12 X 24 OD
2
HORN BRACKET (2)
5
FLAT WASHER, SAE, ZINC-
PLATED
1/4" ID X 0.63
OD
1
HORN BRACKET (1)
6
HEX BOLT, GRADE 8.8, ZINC-
PLATED
M12 X 1.5 X 70
LONG
1
HORN BRACKET (1)
7
LOCK WASHER, SPLIT LOCK,
ZINC-PLATED
M12
1
HORN BRACKET (1)
8
RUBBER EDGE TRIM (U)
8” LONG
1
HORN BRACKET (1)
9
LOCK WASHER, SPLIT LOCK,
ZINC-PLATED
1/4”
1
HORN BRACKET (1)
10
HEX NUT, GRADE 8.8, ZINC-
PLATED
M12 X 1.5
1
HORN BRACKET (1)
11
HEX NUT, GRADE 8.8,
ZINC-PLATED
M6 X 1.0
1
HORN BRACKET (1)
End of Section

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8. 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.
8.1. Relay and Fuse Diagram for Air Horn, Air Compressor, and Air Tank Pressure Switch
Figure 1 - Suggested Ignition Relay Diagram for Air Horn System

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8.2. Suggested Wire Routing for Air Horn, Air Compressor, and Pressure Switch
Figure 2 - Suggested Wire Routing for Horn, Air Compressor, and Pressure Switch
8.3. 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
8.4.1. Find a suitable location for supplied relay(s) and fuse(s). Shown below is an example location under
hood next to battery and near grounding block. Use supplied self-tapping screws, as necessary.
8.4.2. Connect routed wiring to relay(s) and fuse(s), per wiring diagram in Figure 1 shown above
Battery Box
Fuses
Ground Block
Relays Below
Wiring
Fender

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8.5. Route Wiring and Install Horn Button
8.5.1. Route wiring throughout vehicle, per diagrams; however, installer may route as desired.
8.5.2. Insert all wiring into included wire loom and ensure loom is away from all sharp edges, hot vehicle parts
(i.e., exhaust, engine, radiator), and fasten securely to vehicle using zip ties, or equivalent.
NOTE: Do not cut wires to length until 100% sure of length required for final connections.
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 on other end.
CAUTION: Do not install 30-amp fuse until all electrical connections are final.
8.5.4. Find a suitable location for horn push-button (i.e., in dash, center console, etc.); verify location has 1”+ of
clearance behind for terminals. Mark location for drilling.
NOTE: FOR VEHICLES WITH FACTORY UPFITTER SWITCHES:
If your vehicle is equipped with factory upfitter (i.e., auxiliary) switches, you may elect to use them for
your Kleinn Air Horn kit; consult Owners Manual, or dealership for further instructions on what wire
terminals to use and programming required.
8.5.5. Drill a 3/4” hole at location. Route horn button wires to hole then slide push-button retaining nut over
wires and connect per wiring diagram. Install push-button into hole and tighten retaining nut securely on
backside.
8.6. Connect Air Horn Solenoid
8.6.1. Vehicle space constraints make it difficult to connect Air Horn Solenoid in-vehicle; therefore, it is
recommended to cut and connect a section of wiring to Solenoid during bench assembly, then perform
final connection once Air Horn assembly is installed.
End of Section
Terminator Horn Button

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9. Bench Assembly Steps
Complete following steps off vehicle to facilitate final installation.
NOTE: ALL HARDWARE WILL BE SPECIFIED IN INSTRUCTIONS USING ITEM NO.’S FOUND IN PARTS LIST. See Parts
List. Assemble ALL fasteners clean and dry using proper socket and box-end wrench. (Not including Air fittings)
9.1. Horn Bracket Assembly
9.1.1. Using JL-301, install horn drivers onto studs, following Figure 3, using Hardware #3, #4, & #5. Tighten to
75-88 in-lbs.
NOTE: Make sure edges of horn drivers are parallel to edges of brackets shown in Figure 3 below in red.
Figure 3 - Horn Driver Installation onto JL-301
9.1.2. Attach air tubing and wiring now, but do not trim to length until horn bracket is installed.
NOTE: Make sure solenoid orientation matches Figure 3.

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9.1.3. To protect fuel line against potential abrasion during severe off-road use, install rubber trim Hardware
#8 to JL-301 along outer edge shown in red in Figure 4 below; zip tie ends of trim to reliefs circled.
Figure 4 –Rubber Trim shown ziptied to JL-301