Klenn Air Horns RAMHD-230/734, Installation Manual

Page 1: ...RAMHD 230 734 INSTALLATION MANUAL Kleinn Air Horns 2018 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web www Kleinn com REV B 4 8 2021 ...

Page 2: ... Installation and Operation Manual Go to Table of Contents PG 1 41 REV B 4 8 2021 This digital PDF is interactive Please save ink and paper Open interactive manual using Adobe Reader on PC MAC and all smart devices ...

Page 3: ...5 1 Standard Tool List Required 10 5 2 Special Tool List Recommended 10 5 3 Shop Consumables List Recommended 10 6 Parts List 11 6 1 Pre Packaged Electro Mechanical Items 11 6 2 Air Fittings and Related Items 12 6 3 Electrical Small Components and Related Items 14 6 4 Bolt On Brackets and Hardware Fasteners 14 7 Bench Assembly Steps 16 7 1 Unpack and Layout Kit Parts 16 7 2 Disassemble Train Horn ...

Page 4: ...ch Relay to Vehicle 36 10 3 Route Wiring and Install Horn Button 36 10 4 Connect Relay to Wiring 37 10 5 Connect Air Horn Solenoid 37 10 6 Reconnect Vehicle Battery s 37 11 Initial Testing of Kit 38 11 1 Test Air Compressor 38 11 2 Test Train Horns 38 11 3 Test Quick Connect Coupler 38 12 General Operation of Kit 39 12 1 Compressor Operation 39 12 2 Horn Operation 39 13 Routine Maintenance 40 14 W...

Page 5: ...d this Manual This manual covers installation testing and operation of following kit part numbers 1 RAMHD 230 i e 230 Train Horns 2 RAMHD 734 i e 730 Train Horns 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 t...

Page 6: ...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 meanin...

Page 7: ...wire grounding points 3 2 Excluded Vehicles RAMHD 230 734KIT may not be compatible with following RAM vehicles 1 All Crew Cab Long Bed model years listed 2 All Regular Standard Cabs model years listed Kit may be adapted to these vehicles with vehicle modification 1 Small Horn Bracket Drill mounting holes in vehicle chassis at approximate location shown in instructions 2 Compressor Bracket Drill mo...

Page 8: ...edium Horn with Mounting Bracket and Air Solenoid Under driver side front door Bolted to outside of frame rail 2 Hours 2 230 730 Series Small Horn with Mounting Bracket Under driver side rear door Bolted to outside of frame rail 1 2 Hours 3 Air Tank with Mounting Bracket Under passenger side front door Bolted to outside of frame rail 2 Hours 4 6350RC 6450RC Air Compressor with Mounting Bracket Und...

Page 9: ...rew Cab Short Bed 734KIT Shown 4 1 Approximate Installation Time RAMHD 230 734KIT 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 8 12 Hours 1 2 3 4 ...

Page 10: ...Air Fittings to Air Tank 4 Mount Medium Large Horn Drivers to Front Horn Bracket 5 Mount Small Horn Driver to Rear Horn Bracket 6 Mount Air Tank to Bracket 7 Mount Medium Large Horn Bracket Assembly to Frame install Horn Trumpets 8 Mount Small Horn Bracket Assembly to Frame install Horn Trumpet 9 Mount Air Tank Bracket Assembly to Frame 10 Mount Air Compressor Bracket to Frame and Mount Air Compre...

Page 11: ...re Cutter Pliers 5 Wire Strippers 6 Wire Terminal Crimpers 7 Slip Joint Pliers 8 Utility Knife or Utility Razor blade 5 2 Special Tool List Recommended 1 10 100 ft lb torque wrench 2 50 150 in lb torque wrench 3 Multi Meter for 12V DC electrical systems or equivalent 4 12V DC Test Light or equivalent 5 3 Shop Consumables List Recommended 1 Quality Electrical tape 2 Di electric grease for electrica...

Page 12: ...s 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 6350RC 230 ONLY 6350RC Compressor Kit with included hardware and remote air supply line 1 1 6450RC 734 ONLY 6450RC Compressor Kit with included hardware and remote air supply line 2 1 230 230 ONLY 230 Series Horn Kit with included solenoid valve and 1...

Page 13: ...on Air Tank 1 4 NPT X 1 4 Compression Fitting 90 Deg Elbow 5 1 52835 view location on Air Tank 1 4 NPT Drain Valve 6 1 52175 view location on Air Tank 1 4 NPT 175 PSI Safety Valve 7 1 51214L 734 ONLY view location on Air Tank 1 4 NPT X 1 2 Compression Fitting 90 Deg Elbow 8 1 51214R 734 ONLY view location on Air Tank 1 2 NPT FEMALE X 1 4 NPT Reducer Fitting 8 1 51412 230 ONLY view location on Air ...

Page 14: ...4 NPT Pressure Switch 10 1 51414F 1 4 NPT FEMALE X 1 4 Compression Fitting 11 2 25014 230 ONLY 1 4 Air Tubing 12 ft long 11 2 25012 734 ONLY 1 2 Air Tubing 12 ft long 12 1 1302 Quick Connect Air Coupler Kit with relocation bracket 13 1 INF 1 Inflator Kit with Air Hose and Bag 14 1 KLEINN AIR HORN JUICE Thread Sealant for NPT Fittings ...

Page 15: ...Button 16 1 WIRE KIT Full Wire Kit with electrical connectors and zip ties 17 1 WIRE LOOM 20 ft Long 1 4 Wire loom for electrical routing 18 1 1 8 WIRE LOOM 10 ft Long 1 8 wire loom for electrical routing 6 4 Bolt On Brackets and Hardware Fasteners ITEM QTY PART NUMBER DESCRIPTION PICTURE 19 1 RAMHD HARDWARE 1 2 13 Bolts Nuts and Washers for bracket mounting 20 1 4 BOLT TANK HARDWARE 7 16 14 Bolts...

Page 16: ...18 Bolts Nuts and Washers for horn mounting 22 1 RAMHD_HORN LG_BRKT ASSY Medium Large Horn Bracket 23 1 RAMHD_HORN SM_BRKT Small Horn Bracket 24 1 RAMHD_TANK_BRKT ASSY Air Tank Bracket 25 1 RAMHD_COMPRESSOR_BRKT Air Compressor Bracket 26 6 RAMHD_WASHER Washer for Frame Slots 27 1 RAMHD 201 for 2019 RAMHD Compressor Bracket Bolt Tie ...

Page 17: ...pressor box and included hardware 3 Review air tank box and included hardware 4 Review kit mounting brackets and included hardware 5 Review electrical air fittings and included wiring and tubing 7 2 Disassemble Train Horn Kit 1 Remove trumpets from drivers and set aside a Starting with largest trumpet tightly grasp trumpet with both hands and unscrew counter clockwise trumpet may be very tight Rep...

Page 18: ...r box end wrench b Horn mounting plate and fasteners will NOT be re used during installation 4 Remove cut tubing from fittings a Using slip joint pliers or equivalent pull and twist off tubing connected to compression fittings b Depress collar on quick release fitting with one hand then twist and pull plastic tube out with other hand If necessary use slip joint pliers or equivalent to twist and pu...

Page 19: ...e Horn Drivers to Bracket 1 Attach Horn Driver to bracket with Large trumpet and Ore Mount 734KIT Only per below illustration 734KIT Shown a Use Horn Separation Hardware kit i Assemble fasteners clean and dry using proper socket and box end wrench b Do not use Ore Mount Rubber Bushing included in kit Ore Mount 734KIT Only ...

Page 20: ...pipe threads i Hand tighten each fitting then further tighten with wrench 1 4 1 2 turn ii Verify that air flow arrow on Solenoid points to horn driver and facing up b Use Horn Separation Hardware kit and hand tighten fasteners to bracket i Assemble fasteners clean and dry using proper socket and box end wrench ii Final tightening will be completed on vehicle 2 Attach medium horn driver to bracket ...

Page 21: ...aration Hardware kit i Assemble fasteners clean and dry and finger tighten they should be tight enough that horn driver does not move freely but can be repositioned with some hand force ii Final tightening will be completed on vehicle iii Observe correct driver orientation based on specific vehicle Crew Cab Orientation top slots bracket facing to right Mega Cab Orientation bottom slots bracket fac...

Page 22: ... fittings to tank per below illustrations a Apply two small drops of Kleinn Air Horn Juice to each male pipe thread b Hand tighten each fitting then further tighten each 1 4 1 2 turn using proper sized box end wrench adjust as necessary to match fitting orientation shown c Match item numbers to Parts List Go to Fittings List 4 5 9 4 8 7 6 734KIT Only ...

Page 23: ...ents PG 22 41 REV B 4 8 2021 2 Attach air tank to bracket per below illustration a Use 4 Bolt Tank Hardware kit i Assemble fasteners clean and dry tank should not move freely but can be repositioned with some hand force ii Final tightening will be completed on vehicle ...

Page 24: ...erneath vehicle and applying forces to vehicle chassis Follow all recommended safety precautions for raising vehicle consult vehicle owner s manual 8 1 Large Medium Horn Assembly Installation 1 Attach Large Medium Horn bracket assembly onto vehicle chassis per below illustration a Use RAMHD Hardware kit i Finger tighten fasteners only but ensure bracket is sitting entirely flush on chassis b Insta...

Page 25: ...fore aft as necessary to ensure adequate clearance between all trumpets and underbody i Large Horn Trumpet must have minimum 1 4 i e thickness of Bic Pen clearance between underbody floor brace ii Horns can also be repositioned on bracket slots b Hold bracket in correct position and tighten mounting fasteners firmly c Tighten horn mounting fasteners to bracket firmly 3 Attach medium horn trumpet a...

Page 26: ...ab and Mega Cab Orientation 734KIT Shown 8 2 Small Horn Assembly Installation 1 Attach Small Horn bracket assembly onto vehicle chassis per below illustration a Use RAMHD Hardware kit and finger tighten fasteners only b Install Small trumpet into open driver and tighten firmly Crew Cab Orientation FRONT ...

Page 27: ...RAMHD 230 734 Installation and Operation Manual Go to Table of Contents PG 26 41 REV B 4 8 2021 Crew Cab Orientation 734KIT Shown Mega Cab Orientation 734KIT Shown ...

Page 28: ...s per below illustration a Move bracket up down and fore aft as necessary to ensure adequate clearance between trumpet and underbody i Horn can also be repositioned on bracket slots b Hold bracket in correct position and tighten mounting fasteners firmly c Tighten horn mounting fasteners to bracket firmly Crew Cab Orientation 734KIT Shown FRONT ...

Page 29: ...hicle chassis requires hands to be near exhaust system make sure vehicle exhaust is cool enough to touch before installation 1 Attach Air Tank assembly onto vehicle chassis per below illustration a Use RAMHD Hardware kit i Ensure bracket is sitting entirely flush on chassis and finger tighten fasteners Crew Cab and Mega Cab Orientation 734KIT Shown FRONT 4 LONG BOLT ...

Page 30: ...d tank ii Air Tank must have minimum 1 4 clearance between underbody and rocker panels iii Reposition Tank up down on bracket slots if necessary b Mark proper location of Air Tank on Bracket using grease pencil or similar 3 Remove Air Tank Bracket from chassis and firmly tighten Air Tank to Bracket mounting bolts a Use alignment marks made in previous step 4 Re install Air Tank Bracket to chassis ...

Page 31: ... Hold bracket in position and firmly tighten fasteners Crew Cab Orientation 2 Attach Compressor to bracket per below illustration b Use included fasteners i Tighten fasteners firmly 3 Attach 51414F 1 4 female compression fitting to end of air compressor hose per below illustration c Apply two small drops of Kleinn Air Horn Juice to each male pipe thread d Hand tighten each fitting then further tig...

Page 32: ...RAMHD 230 734 Installation and Operation Manual Go to Table of Contents PG 31 41 REV B 4 8 2021 Crew Cab Orientation 734KIT Shown Mega Cab Orientation 734KIT Shown ...

Page 33: ...re hole One bolt sticks out of this square hole the other bolt sticks out of the round hole just in front of it Use your fingers to hold the tie plate against the inside of the frame tube via the square thru hole Attach bracket to frame using bolt tie plate and 7 16 hardware supplied as shown below Use one of the sets of slots as shown below Use the forward set of slots left image below if your tr...

Page 34: ... zip ties or equivalent 2 Connect air compressor outlet to air tank using supplied 1 4 tubing per below illustration 734KIT Shown 3 Connect Medium Air Horn solenoid to air tank outlet using supplied 1 2 tubing 734KIT or 1 4 tubing 230KIT 4 Connect Remote Quick Connect kit to air tank outlet per below illustration a Route and attach Quick Connect Coupler Kit to vehicle as desired I e under hood nea...

Page 35: ... location away from road spray water excessive dust etc 6 Re connect all horns using supplied 1 4 tubing per below illustration a Cut all tubing to length using sharp utility blade razor blade tubing cutter or equivalent ends must be square and not deformed before attaching to air fittings i For further instruction on properly installing into fittings reference this SMC Video 1 4 Tubing to Remote ...

Page 36: ...View this general Kleinn 6450RC installation manual for more information 8 View this general Kleinn 730 Horn Kit installation manual for more information 1 2 Tubing from Air Tank 734KIT 1 4 Tubing from Air Tank 230KIT 1 4 Tubing to either Small or Large Horn 1 4 Tubing to either Small or Large Horn ...

Page 37: ...llow wire to other wire on pressure switch route to vehicle interior and connect it to a fused 12v switched power source i e open accessory spot on fuse block 10 3 Route Wiring and Install Horn Button a Locate red 10 gauge power wire this wire will be run to battery and down to compressor bracket Wire should be routed down passenger side frame rail away from all exhaust for later connection to com...

Page 38: ...inal is properly grounded by either touching bare metal or via self tapping screw c Connect Pin 86 to supplied Yellow wire and to pressure switch wire on Air Tank either wire can be connected Connect remaining yellow wire to other wire on pressure switch route to vehicle interior and connect it to a fused 12v switched power source i e open accessory spot on fuse block 10 5 Connect Air Horn Solenoi...

Page 39: ...Verify all tubing and electrical wire is securely fastened to vehicle brackets or kit parts if necessary use extra zip ties to hold tubing and wire in place c Ensure all nearby persons have adequate hearing protection and provide courtesy warning to neighbors or others in vicinity WARNING NEVER operate train horns with ears close to trumpets or in an enclosed space without substantial hearing prot...

Page 40: ...discharge of vehicle s battery and for best performance keep vehicle s engine running while using air compressor for any prolonged use i e filling tires using air tools etc 12 2 Horn Operation a Allow Air Compressor to run until it shuts off automatically i e Air Tank is full or for at least one minute in between horn activations b Press Horn Button to activate Horns i Horn sound loudness will tap...

Page 41: ...limates where road salts are used 3 Yearly or every 12000 miles check electrical and air fitting connections and wires for abrasion corrosion or other damage Replace damaged components NOTE if system runs continuously or turns on unexpectedly leaks or intermittent electrical connection may be present 4 Monthly or every 10 hours of compressor run time drain moisture from air tank using drain valve ...

Page 42: ...nty Information Thank you for purchasing this RAMHD 230 734 Shall you experience any unexpected problems during installation or have problems with any part at any time please contact Kleinn support Kleinn Air Horns 2020 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web www Kleinn com ...