Klenn Air Horns RAMHD-230KIT, Installation Manual

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...