Kleinn Air Horns RNGR-102-1/220 User manual

RNGR-102-1/220
INSTALLATION MANUAL
REV: IR 02/15/2022
© Kleinn Air Horns 2021, All Rights Reserved
PO Box 91278 Tucson, AZ 85752
Phone: [phone]
Web: https://www.kleinn.com

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REV: IR 02/15/2022
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RNGR-102-1/220
Installation & Operation Manual
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Table of Contents
1 How to Use This Manual.....................................................................................................................................5
1.1 Interactive Manual Using Adobe Reader....................................................................................................5
1.2 Your SKU Number & this Manual ...............................................................................................................5
1.2.1 RNGR-102-1/220.................................................................................................................................5
1.2.2 Warranty Registration ........................................................................................................................5
1.3 Illustration/Photo Details & Orientation....................................................................................................6
2 Safety First ..........................................................................................................................................................6
3 Application Chart................................................................................................................................................7
3.1 Bolt-On Vehicle List ....................................................................................................................................7
3.2 Excluded Vehicles .......................................................................................................................................7
3.3 Aftermarket Product Compatibility............................................................................................................7
4 Installation Overview..........................................................................................................................................8
4.1 Kit Layout & System Location(s).................................................................................................................8
4.2 Install Process Outline ..............................................................................................................................10
4.3 Approximate Installation Time .................................................................................................................11
5 List of Tools & Supplies.................................................................................................................................... 12
5.1 Standard Tool List (Required) ...................................................................................................................12
5.2 Special Tool List (Recommended) ............................................................................................................12
5.3 Shop Consumables List (Recommended) .................................................................................................12
6 Parts List .......................................................................................................................................................... 13
6.1 Review Parts List.......................................................................................................................................13
6.2 Pre-Packaged Kit Items.............................................................................................................................13
6.3 Air Fittings & Related Items......................................................................................................................14
6.4 Electrical Components & Related Items...................................................................................................15
6.5 Mounting Brackets & Special Hardware...................................................................................................16
6.6 Hardware, Fasteners, & Soft Parts ...........................................................................................................17
7 Bench Assembly............................................................................................................................................... 18
7.1 Assemble Air Fittings to Air Tank..............................................................................................................18
7.2 Assemble Air Tank to Tank Brackets.........................................................................................................19
7.3 Assemble Air Filter to Air Compressor .....................................................................................................19
7.4 Assemble Air Compressor to Compressor Bracket...................................................................................20
7.5 Disassemble Trumpets from Air Horn Drivers..........................................................................................21

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RNGR-102-1/220
Installation & Operation Manual
7.6 Assemble Air Horn Driver to Horn
Bracket..................................................................................................................................................................21
8 On-Vehicle Assembly, Mechanical .................................................................................................................. 22
8.1 Install Air Tank on Vehicle ........................................................................................................................22
8.2 Install Air Compressor on Vehicle.............................................................................................................23
8.3 Install Horns on Vehicle............................................................................................................................24
8.4 Route Air Hose and Install Remote Quick-Connect Coupler ....................................................................25
9 On-Vehicle Electrical Installation..................................................................................................................... 26
9.1 Relay & Fuse Diagram for Air Horn System ..............................................................................................26
9.2 Disconnect Vehicle Battery(s)...................................................................................................................27
9.3 Connect Wires to Fuse & Relay ................................................................................................................27
9.4 Install Horn Button ...................................................................................................................................27
9.5 Connect Pressure Switch ..........................................................................................................................28
9.6 Connect Air Compressor...........................................................................................................................28
9.7 Connect Air Horn Solenoid(s) ...................................................................................................................28
9.8 Secure Wiring to Vehicle ..........................................................................................................................28
10 Final Steps & Testing ................................................................................................................................... 29
10.1 Reconnect Vehicle Battery(s) ...................................................................................................................29
10.2 Test Air Compressor .................................................................................................................................29
10.3 Test Train Horns........................................................................................................................................29
10.4 Test Quick Connect Coupler .....................................................................................................................29
11 General Operation....................................................................................................................................... 30
11.1 Compressor Operation .............................................................................................................................30
11.2 Horn Operation.........................................................................................................................................30
12 Routine Maintenance .................................................................................................................................. 30
13 Warranty Information ................................................................................................................................. 31
14 Record of Revisions ..................................................................................................................................... 32
END OF TABLE OF CONTENTS

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RNGR-102-1/220
Installation & Operation Manual
1How to Use This Manual
1.1 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.
Hyperlinks also allow users to jump to specific spots in within the document.
•Includes 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 quick navigation 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
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On Android/iOS, and Windows devices:
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1.2 Your SKU Number & this Manual
This manual covers the installation, testing, and operation of following SKU part numbers
1.2.1 RNGR-102-1/220
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
1.2.2 Warranty Registration
Please register your kit online at https://kleinn.com/warranty/ to expedite any future warranty claims.

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Installation & Operation Manual
1.3 Illustration/Photo Details &
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 the manual, yellow arrows with text reading “FRONT” may be
present over illustrations and pictures. These arrows specify direction
toward the front of the vehicle and provide clarity as to how illustration is
viewed.
END OF SECTION
2Safety First
Read manual thoroughly before starting installation of this kit. Verify that you have all parts listed, and that you
clearly understand the installation procedure. Contact Kleinn technical support with 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/or 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.
END OF SECTION
FRONT

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RNGR-102-1/220
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3Application Chart
3.1 Bolt-On Vehicle List
RNGR-102-1/220 is a direct-fit bolt-on air horn system for the following vehicles.
MODEL YEAR
MODEL
DRIVE
ENGINE
BODY
TRIM
2019-2021
Ranger
All
All
All
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.
3.2 Excluded Vehicles
The following vehicles have been found to be incompatible with the designed kit:
No incompatible configurations are known at this time.
3.3 Aftermarket Product Compatibility
This kit has been designed to work with the following aftermarket products:
•Power running boards/steps
•Fix running boards/steps
This kit has not been designed to work with the following aftermarket products:
•No incompatibilities are known at this time.
NOTE: Review this manual in full before unpacking items to verify correct space and mounting locations
exist with your aftermarket product(s). To install this kit alongside your other aftermarket product(s),
modification to the included parts, your vehicle, or your aftermarket product(s) may be required.
END OF SECTION

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RNGR-102-1/220
Installation & Operation Manual
4Installation Overview
4.1 Kit Layout & System Location(s)
RNGR-102-1/220 consists of the following components, located on vehicle as follows:
ITEM DESCRIPTION VEHICLE LOCATION
APROX.
INSTALL TIME
1
6275RC Air Compressor (102-1 KIT)
6450RC Air Compressor (220 KIT)
Passenger-side rear bed pocket 1 hr.
2 1.5 Gal. Air Tank Driver-side rear bed pocket 2 hrs.
3
102-1 Air Horns (102-1 KIT)
220 Air Horns (220 KIT)
Under cab 2 hrs.
Figure 1: Isometric Overlay of Kit Locations

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RNGR-102-1/220
Installation & Operation Manual
Figure 2: Under Vehicle View (Compressor) – Behind Rear Wheel Well (Passenger Side)
Figure 3: Under Vehicle View (Horns) – Under Driver Side Seating Area (220 Horns Shown)

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RNGR-102-1/220
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Figure 4: Under Vehicle View (Air Tank) – Behind Rear Wheel Well (Driver Side)
4.2 Install Process Outline
For person(s) with prior experience installing RNGR-102-1/220, a reminder of the install steps is provided
below:
UNPACKAGE KIT (SECTION 6)
1. Layout and organize all parts
BENCH ASSEMBLY (SECTION 8)
2. Assemble air fittings to air tank
3. Assemble air filter to air compressor
4. Attach compressor to compressor bracket
5. Attach air tank to tank brackets
6. Assemble horn (DRIVERS)to horn bracket
ON-VEHICLE MECHANICAL ASSEMBLY (SECTION 9)
7. Mount compressor bracket to vehicle
8. Mount tank brackets to vehicle
9. Mount horn bracket to vehicle
10. Attach horn trumpets to the horn drivers (220KIT ONLY)
11. Connect pneumatic components & route air tubing
ON-VEHICLE ELECTRICAL ASSEMBLY (SECTION 10)
12. Install relay & fuse, route wiring, and install horn button
13. Connect all electrical items (air horn(s), pressure switch, air compressor)
FINAL STEPS (SECTION 11)
14. Test system; adjust as needed