background image

 

 

RAMHD-230/734KIT

 

 

  Installation and Operation Manual

 

Go to Table of Contents

 

PG 9/41 

REV: BETA (2/19/2018) 

4.2.

 

***Quick Install Outline 

For person(s) with experience installing Kleinn bolt-on kits, RAMHD-230/734KIT can be installed in an order 
similar to below: 

1.

 

Route wiring, install Relay, and Horn Switch 

2.

 

Disassemble 230/730 Horn Kit (i.e., separate drivers from trumpets and horn mounting plate) 

3.

 

Assemble 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 Compressor to Bracket 

11.

 

Route Air Tubing, Quick Connect Coupler, Air Compressor filter, and connect all Pneumatic components 

12.

 

Connect wiring to all components 

13.

 

Test System and adjust, as needed 

 

 

Summary of Contents for RAMHD-230KIT

Page 1: ...RAMHD 230 734KIT INSTALLATION MANUAL Kleinn Air Horns 2018 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web www Kleinn com REV BETA 2 19 2018...

Page 2: ...Installation and Operation Manual Go to Table of Contents PG 1 41 REV BETA 2 19 2018 This digital PDF is interactive Please save ink and paper Open interactive manual using Adobe Reader on PC MAC and...

Page 3: ...0 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 Rel...

Page 4: ...tach 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...

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

Page 6: ...nd 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...

Page 7: ...wire grounding points 3 2 Excluded Vehicles RAMHD 230 734KIT may not be compatible with following DODGE vehicles 1 All Crew Cab Long Bed model years listed 2 All Regular Standard Cabs model years lis...

Page 8: ...d Medium 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...

Page 9: ...Crew 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...

Page 10: ...ble 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 Assemb...

Page 11: ...Wire 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 to...

Page 12: ...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 230KIT ONLY 6350RC Compressor Kit with includ...

Page 13: ...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 734KIT ONLY...

Page 14: ...NPT Pressure Switch 10 1 51414F 1 4 NPT FEMALE X 1 4 Compression Fitting 11 2 25014 230KIT ONLY 1 4 Air Tubing 12 ft long 11 2 25012 734KIT ONLY 1 2 Air Tubing 12 ft long 12 1 1302 Quick Connect Air...

Page 15: ...n 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 r...

Page 16: ...HORN SEPARATION HARDWARE 5 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 A...

Page 17: ...ompressor 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...

Page 18: ...or 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 conne...

Page 19: ...rge 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 cle...

Page 20: ...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 7...

Page 21: ...0 734KIT Installation and Operation Manual Go to Table of Contents PG 20 41 REV BETA 2 19 2018 Crew Cab Orientation top slots bracket facing to right Mega Cab Orientation bottom slots bracket facing t...

Page 22: ...ir 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 si...

Page 23: ...nts PG 22 41 REV BETA 2 19 2018 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 repositione...

Page 24: ...underneath 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 Att...

Page 25: ...ustration a Move bracket up down and 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...

Page 26: ...Cab 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 tig...

Page 27: ...RAMHD 230 734KIT Installation and Operation Manual Go to Table of Contents PG 26 41 REV BETA 2 19 2018 Crew Cab Orientation 734KIT Shown Mega Cab Orientation 734KIT Shown...

Page 28: ...ers 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 i...

Page 29: ...vehicle 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...

Page 30: ...und 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 g...

Page 31: ...REV BETA 2 19 2018 8 4 Compressor and Bracket Installation 1 Attach Compressor bracket onto vehicle chassis per below illustration a Use RAMHD Hardware kit i Ensure bracket is parallel to frame i e l...

Page 32: ...RAMHD 230 734KIT Installation and Operation Manual Go to Table of Contents PG 31 41 REV BETA 2 19 2018 Crew Cab Orientation 734KIT Shown Mega Cab Orientation 734KIT Shown...

Page 33: ...b Use included fasteners i Tighten fasteners firmly 3 Attach 51414F 1 4 female compression fitting to end of air compressor hose per above illustration c Apply two small drops of Kleinn Air Horn Juic...

Page 34: ...ng 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...

Page 35: ...in 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 tubi...

Page 36: ...7 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...

Page 37: ...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 3 Route Wiring and Install Horn But...

Page 38: ...erminal 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 Conne...

Page 39: ...b 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 adequat...

Page 40: ...t 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 All...

Page 41: ...climates 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 syste...

Page 42: ...rranty Information Thank you for purchasing this RAMHD 734KIT Shall you experience any unexpected problems during installation or have problems with any part at any time please contact Kleinn support...

Reviews: