Kleinn Air Horns RAMHD-734KIT User manual

RAMHD-734KIT
INSTALLATION MANUAL
© Kleinn Air Horns 2021, All rights reserved.
PO Box 91278 Tucson, AZ 85752
Phone: [phone]
Web: www.Kleinn.com
REV: A (6/11/2021)

RAMHD-734KIT
Installation and Operation Manual
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RAMHD-734KIT
Installation and Operation Manual
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Table of Contents
1. How to Use this Manual .....................................................................................................................................4
2. Safety First..........................................................................................................................................................4
3. Application Chart................................................................................................................................................5
4. Kit Installation Overview ....................................................................................................................................6
4.1. Approximate Installation Time...................................................................................................................7
5. List of Tools and Supplies ...................................................................................................................................8
5.1. Standard Tool List (Required).....................................................................................................................8
5.2. Special Tool List (Recommended) ..............................................................................................................8
5.3. Shop Consumables List (Recommended)...................................................................................................8
6. Parts List .............................................................................................................................................................9
7. Bench Assembly Steps..................................................................................................................................... 13
7.1 Unpack and Layout Kit Parts.................................................................................................................... 13
7.2 Disassemble Train Horn Kit...................................................................................................................... 13
7.3 Mount Medium and Large Horn Drivers to Bracket................................................................................ 15
7.4 Mount Small Horn Driver to Bracket....................................................................................................... 17
7.5 Mount Air Tank to Bracket ...................................................................................................................... 18
8. On-Vehicle Mechanical Assembly Steps.......................................................................................................... 20
8.1 Large-Medium Horn Assembly Installation............................................................................................. 20
8.2 Small Horn Assembly Installation............................................................................................................ 23
8.3 Air Tank Assembly Installation ................................................................................................................ 26
8.4 Compressor and Bracket Installation ...................................................................................................... 29
9. On Vehicle Air Line Installation ....................................................................................................................... 32
10. On Vehicle Electrical Installation................................................................................................................. 35
10.1. Disconnect Vehicle Battery(s).............................................................................................................. 35
10.2. Attach Relay to Vehicle........................................................................................................................ 35
10.3. Route Wiring and Install Horn Button................................................................................................. 35
10.4. Connect Relay to Wiring...................................................................................................................... 36
10.5. Connect Air Horn Solenoid .................................................................................................................. 36
10.6. Reconnect Vehicle Battery(s) .............................................................................................................. 36
11. Initial Testing of Kit...................................................................................................................................... 37
11.1. Test Air Compressor ............................................................................................................................ 37
11.2. Test Train Horns................................................................................................................................... 37

RAMHD-734KIT
Installation and Operation Manual
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11.3. Test Quick Connect Coupler ................................................................................................................ 37
12. General Operation of Kit ............................................................................................................................. 38
12.1. Compressor Operation ........................................................................................................................ 38
12.2. Horn Operation.................................................................................................................................... 38
13. Routine Maintenance.................................................................................................................................. 39
14. Warranty Information ................................................................................................................................. 40

RAMHD-734KIT
Installation and Operation Manual
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1. How to Use this Manual
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2. 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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Installation and Operation Manual
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3. Application Chart
RAMHD-734KIT is a 100%** direct bolt-on aftermarket product for all DODGE vehicles listed in below chart
MODEL YR
MODEL
DRIVE
ENGINE
BODY
TRIM
2014-2021
RAM 2500
2WD, 4WD
ALL
Crew Cab (short
bed**), Mega Cab
ALL
2014-2021
RAM 3500
2WD, 4WD,
DUALIE
ALL
Crew Cab (short
bed**), Mega Cab
ALL
**Exclusions:
All vehicles listed may require drilling holes for ground wires and installing switches, based on preference of
installed switch locations and wire grounding points.
Crew Cab Long Bed, or Regular/Standard Cab frames; these frames will require drilling holes to attach following
brackets. Contact Kleinn sales for more information.
1. Small Horn Bracket –drill mounting holes for hardware in approximate location shown in instructions
2. Compressor Bracket –drill mounting holes for hardware in approximate location shown in instructions
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.

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Installation and Operation Manual
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4. Kit Installation Overview
RAMHD-734KIT consists of the following major components, located on vehicle per following pictures and chart
ITEM
DESCRIPTION
PICTURE
MOUNTING
LOCATION
APPROX.
INSTALL TIME
1
730 Series Large and
Medium Horn with
Mounting Bracket and Air
Solenoid
Under driver side
front door.
Bolted to outside
of frame rail.
2+ Hours
2
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
Air Compressor with
Mounting Bracket
Under passenger
side rear door.
Bolted to outside
of frame rail.
1-2 Hours
Top View –Ram 2500 Crew Cab Short Bed
4
3
1
2

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Installation and Operation Manual
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Driver Side View –2014 Ram 2500 Crew Cab Short Bed
Passenger Side View –2014 Ram 2500 Crew Cab Short Bed
4.1. Approximate Installation Time
RAMHD-734KIT is a multi-faceted product consisting of multiple mechanical, electrical, and pneumatic
components.
For a typical home mechanic, or auto enthusiast, a professional installation job with setup and testing of
final product, is estimated to take:
•8-12 Hours
1
2
3
4

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5. List of Tools and Supplies
5.1. Standard Tool List (Required)
1. Basic mechanic’s 3/8” drive socket sets with extensions
a. Inch Size Sockets (1/4” – 1” Hex)
b. Metric Size Sockets (6mm –20mm Hex)
2. Basic mechanic’s combination wrenches (box/open-end)
a. Inch Size Wrenches (1/4” – 1” Hex)
b. Metric Size Wrenches (6mm –20mm Hex)
3. Basic mechanic’s screwdriver set (Philips, Flat Head)
4. Diagonal Cutter/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. torque wrench
a. For English to Metric torque conversions, reference Norbar online calculator, or similar.
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 electrical connections
3. Heat Shrink tubing for electrical connections
4. Sand Paper, or Wire Brushes for installing ground wires
5. Extra plastic zip ties > 6” long
6. Extra NPT sealant (i.e., Kleinn Air Horn Juice, Teflon tape, etc.)
7. Touch-up paint for frame/chassis
8. Typical cleanup supplies

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Installation and Operation Manual
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6. Parts List
RAMHD-734KIT includes following items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
1
1
6450RC
6450RC Compressor Kit,
with included hardware,
and remote air supply
line
2
1
730
730 Series Horn Kit, with
included solenoid/valve,
and 1/4” Air Tubing, 12
ft. long
3
1
6355RT
Air Tank
4
2
25014
1/4” Air Tubing, 12 ft.
long
5
2
51414L
(view location on Air Tank)
1/4” NPT X 1/4”
Compression Fitting, 90
Deg Elbow
6
1
52835
(view location on Air Tank)
1/4” NPT, Drain Valve
7
1
52175
(view location on Air Tank)
1/4” NPT, 175 PSI Safety
Valve