Kleinn Air Horns SDKIT17-230STD User manual

SDKIT17-230/734STD
INSTALLATION MANUAL
© Kleinn Air Horns 2020, All rights reserved.
PO Box 91278 Tucson, AZ 85752
Phone: [phone]
Web: www.Kleinn.com
REV: BETA (4/13/2020)

SDKIT17-230/734STD
Installation and Operation Manual
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SDKIT17-230/734STD
Installation and Operation Manual
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Table of Contents
1. LIST OF FIGURES .................................................................................................................................................5
2. How to Use this Manual .....................................................................................................................................6
2.1. Interactive Manual using Adobe Reader....................................................................................................6
2.2. Your Kit SKU Number and this Manual.......................................................................................................6
2.3. Illustration/Photo Details and Orientation.................................................................................................6
3. Safety First..........................................................................................................................................................7
4. Application Chart................................................................................................................................................8
4.1. Bolt-On Vehicle List ....................................................................................................................................8
4.2. **Excluded Vehicles ...................................................................................................................................8
4.3. Aftermarket Product Compatibility............................................................................................................8
5. Installation Overview..........................................................................................................................................9
5.1. Kit Layout and System Location(s)..............................................................................................................9
5.2. Install Process Outline.............................................................................................................................. 11
5.3. Approximate Installation Time................................................................................................................ 11
6. List of Tools and Supplies ................................................................................................................................ 12
6.1. Standard Tool List (Required).................................................................................................................. 12
6.2. Special Tool List (Recommended) ........................................................................................................... 12
6.3. Shop Consumables List (Recommended)................................................................................................ 12
7. Parts List .......................................................................................................................................................... 13
7.1. Before Starting, Review Parts List ........................................................................................................... 13
7.2. Pre-Packaged Electro-Mechanical Kit Items............................................................................................ 13
7.3. Air Fittings and Related Items ................................................................................................................. 14
7.4. Electrical Small Components and Related Items..................................................................................... 15
7.5. Bolt-On Mounting Brackets & Special Hardware .................................................................................... 15
7.6. Hardware, Fasteners and Soft Parts........................................................................................................ 16
7.7. Add-On Accessories................................................................................................................................. 16
8. Bench Assembly............................................................................................................................................... 17
8.1. Disassemble Trumpets from Air Horn Drivers......................................................................................... 17
9. On-Vehicle Mechanical Assembly ................................................................................................................... 18
9.1. Remove Spare Tire Lift Mechanism......................................................................................................... 18
9.2. Install Air Horn Bracket (SD17-304)......................................................................................................... 20
9.3. Install Air Horn Ore Support Bracket (SD17-306) –734STD ONLY.......................................................... 21

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9.4. Install Air Horn Sub-Assembly ................................................................................................................. 22
9.5. Install Air Tank Fittings on Air Tank & Connect Air Tubing...................................................................... 23
9.6. Final Trumpet Installation ....................................................................................................................... 24
10. On-Vehicle Electrical Installation..................................................................................................................... 25
10.1. Relay and Fuse Diagram for Air Horn System.......................................................................................... 25
10.2. Suggested Wire Routing for Air Horn System ......................................................................................... 26
10.3. Disconnect Vehicle Battery(s).................................................................................................................. 26
10.4. Connect Wiring to Fuse and Relay........................................................................................................... 26
10.5. Install Horn Button .................................................................................................................................. 27
10.6. Connect Pressure Switch......................................................................................................................... 27
10.7. Connect Air Compressor.......................................................................................................................... 27
10.8. Connect Air Horn Solenoid(s) .................................................................................................................. 27
10.9. Secure Wiring to Vehicle ......................................................................................................................... 27
11. Final Steps & Testing ....................................................................................................................................... 28
11.1. Reconnect Vehicle Battery(s) .................................................................................................................. 28
11.2. Test Air Compressor ................................................................................................................................ 28
11.3. Test Train Horns....................................................................................................................................... 28
11.4. Test Quick Connect Coupler .................................................................................................................... 28
12. General Operation........................................................................................................................................... 29
12.1. Compressor Operation ............................................................................................................................ 29
12.2. Horn Operation........................................................................................................................................ 29
13. Routine Maintenance...................................................................................................................................... 29
14. Warranty Information ..................................................................................................................................... 30
End of Table of Contents

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1. LIST OF FIGURES
Figure 1 –Above Vehicle View Showing Kit Layout (2020 F-350 Crew Cab Short Bed Shown) .................................9
Figure 2 –Under Vehicle View of Air Horn Installed –without Air Tank & Compressor (2017 F-250 Shown)....... 10
Figure 3 –Removing Trumpets from Air Horn Drivers, Exploded View.................................................................. 17
Figure 4 –Exploded view of Spare Tire Mechanism from Ford Parts (2017 F-250/F-350 shown).......................... 18
Figure 5 –Underbody view of Spare Tire Mechanism and Crossmember (2017 F-250 shown)............................. 19
Figure 6 –Underbody view of Crossmember with Mounting Holes and Bolts installed (2017 F-250 shown) ....... 20
Figure 7 –Installing SD17-304 Bracket (Exploded view shown).............................................................................. 20
Figure 8 –Installing Horn Ore Support Bracket SD17-306 (Exploded view shown) –734STD ONLY...................... 21
Figure 9 –Air Horn Sub-Assembly installation (Exploded View of 730 Horn with Ore Supports shown)............... 22
Figure 10 –Installing Air Fittings onto Air Tank (Exploded view shown as if installed in Vehicle).......................... 23
Figure 11 –Re-attaching Trumpets (Exploded View shown as if installed in vehicle) ............................................ 24
Figure 12 –Suggested Ignition Relay Diagram for Air Horn System (230/730 Horn Shown).................................. 25
Figure 13 –Suggested Wire Routing for Horn, Air Compressor, and Pressure Switch (SDKIT17-734STD Shown) . 26
Figure 14 –Relay and Fuse location example under hood (Shown in example vehicles)....................................... 26
Figure 15 –Horn Button Installed in Dash and OE Upfitter Switches (Shown in example vehicles) ...................... 27
End of Figures

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2. How to Use this Manual
2.1. 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
oIncludes 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 quickly navigating 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
To install Adobe Reader ®
On PC, or Mac
•visit https://get.adobe.com/reader/otherversions/
On Android, iPhone/iPad, and Windows devices,
•visit https://acrobat.adobe.com/us/en/acrobat/mobile-app.html
2.2. Your Kit SKU Number and this Manual
This manual covers installation, testing, and operation of following SKU part numbers
2.2.1. SDKIT17-230STD (i.e., 230 Train Horn)
2.2.2. SDKIT17-734STD (i.e., 730 Train Horn)
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.
2.3. Illustration/Photo Details and 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 manual yellow arrows with text reading “FRONT”, may be present over
illustrations and pictures. These arrows specify direction toward front of vehicle and
provide clarity to how illustration is viewed.
End of Section
FRONT

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3. 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
End of Section

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4. Application Chart
4.1. Bolt-On Vehicle List
SDKIT17-230/734STD is a direct bolt-on aftermarket product for FORD vehicles listed in below chart; every effort
has been made to verify correct fitment on these vehicles in their factory, non-modified conditions.
MODEL YR
MODEL
DRIVE
ENGINE
BODY
TRIM
2017-2020
F-250 SUPER DUTY
ALL
ALL
ALL
ALL**
2017-2020
F-350 SUPER DUTY
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.
4.2. **Excluded Vehicles
4.2.1. N/A
4.3. Aftermarket Product Compatibility
4.3.1. This kit has been designed to be compatible with following products from leading manufacturers:
•Most aftermarket suspension systems that directly-bolt on (i.e., utilize OE mounting points)
•Aftermarket power steps and rocker steps/running boards
•Aftermarket front bumpers
•Aftermarket rear bumpers
4.3.2. This kit has NOT been designed to be compatible with any of the following products:
•Any aftermarket product that occupies space where Spare Tire resides
•Aftermarket exhaust systems
NOTE: Review this manual in full before unpacking items and verify correct space and mounting locations
exist with your aftermarket product(s). To install this kit alongside your other aftermarket product(s),
modification to included parts, your vehicle, or aftermarket product(s) may be required.
End of Section

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5. Installation Overview
5.1. Kit Layout and System Location(s)
SDKIT17-230/734STD consists of following components, located on vehicle, as follows:
ITEM
DESCRIPTION
VEHICLE LOCATION
MOUNTING
METHOD
APPROX.
INSTALL TIME
1
6450RC Air Compressor
***OBA Kit
Underbody, Passenger Side
(near Spare Tire)
Bracket bolts to Frame
rail
2-4 Hours
2
3.0 Gal. Air Tank
***OBA Kit
Underbody, Driver Side
(behind Rear Axle)
Bracket bolts to both
Frame Rails
2-4 Hours
3
230/730 Series Triple
Horn with Air Solenoids
In place of Spare Tire
(in front of rear Bumper)
Bracket bolts to Frame
Crossmember
1-2 Hours
NOTE: Kleinn SD17OBA-6450 is required to be installed before, or along side this kit.
Click below link to visit Kleinn’s website, including downloading instructions.
https://kleinn.com/product/onboard-air-horn-system-for-2017-2018-ford-f-250-f-350/
Figure 1 –Above Vehicle View Showing Kit Layout (2020 F-350 Crew Cab Short Bed Shown)
2
3
FRONT

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Figure 2 –Under Vehicle View of Air Horn Installed –without Air Tank & Compressor (2017 F-250 Shown)
FRONT

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5.2. Install Process Outline
For person(s) with prior experience installing SDKIT17-230/734STD, a reminder of install steps are listed
below:
UNPACKAGE KIT (SECTION 7)
1. Layout and organize all parts on bench
BENCH ASSEMBLY (SECTION 8)
2. Remove Air Horn Trumpets from Air Horn sub-assembly
ON-VEHICLE, MECHANICAL (SECTION 9)
3. Install SD17OBA-6450; reference SDKIT17-230/734 Installation & Operation manual
4. Remove Spare Lift Mechanism
5. Install Air Horn Bracket (SD17-304)
6. Install Air Horn Ore Support Bracket (SD17-306) –734STD ONLY
7. Install Air Horn Sub-Assembly
8. Install Air Fittings on Air Tank; if SD17OBA-6450 is NOT already installed, assemble new Air Fittings to Air
Tank during Bench Assembly
9. Connect Air Tubing to Air Tank and Electrical Wiring
ON-VEHICLE, ELECTRICAL (SECTION 10)
10. Install Relay & Fuse, route Wiring, and install Horn Button
11. Connect all Electrical items (Air Horn, Pressure Switch, Air Compressor)
FINAL STEPS (SECTION 11)
12. Install Trumpets onto Air Horn Drivers & Final Tighten Air Horns
13. Test system and adjust, as needed
5.3. Approximate Installation Time
SDKIT17-230/734STD is a multi-faceted product consisting of mechanical, electrical, and pneumatic
components.
For a typical home mechanic, auto enthusiast, or technician installing this kit for first time, a professional
installation job with setup and testing of final product, is estimated to take:
•6-12 Hours
End of Section

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6. List of Tools and Supplies
6.1. Standard Tool List (Required)
6.1.1. Basic mechanic’s 3/8” drive socket sets with extensions
•Inch Size Sockets (1/4” – 1” Hex)
•Metric Size Sockets (6mm –20mm Hex)
6.1.2. Basic mechanic’s combination wrenches (box/open-end)
•Inch Size Wrenches (1/4” – 1” Hex)
•Metric Size Wrenches (6mm –20mm Hex)
6.1.3. Basic mechanic’s screwdriver set (Philips, Flat Head)
6.1.4. Diagonal Cutter/Wire Cutter Pliers
6.1.5. Wire Strippers
6.1.6. Wire Terminal Crimpers
6.1.7. Slip-Joint Pliers
6.1.8. Vise Grips, or Locking Pliers
6.1.9. Small pry bar, or large flat blade screwdriver
6.1.10. Utility Knife, or Utility Razor blade
6.1.11. Magnetic retrieval tool
6.2. Special Tool List (Recommended)
6.2.1. Power Hand Grinder, Air Grinder with Cut-Off wheel, or Hacksaw
6.2.2. 10-100 ft-lbs. torque wrench
6.2.3. 20-150 in-lbs. torque wrench
6.2.4. Multi-Meter for 12V DC electrical systems, or equivalent
6.2.5. 12V DC Test Light, or equivalent
6.2.6. Trim Panel Tool, for removing wiring and body clips, when needed
6.3. Shop Consumables List (Recommended)
6.3.1. Quality Electrical tape
6.3.2. Di-electric grease for electrical connections
6.3.3. Heat Shrink tubing for electrical connections
6.3.4. Medium-Strength ThreadLocker (i.e., Blue Loctite® PN 242), or equivalent
6.3.5. Low-Strength ThreadLocker (i.e., Purple Loctite® PN 222), or equivalent
6.3.6. Black/Clear Silicone for drilling holes in body
6.3.7. Sand Paper, or Wire Brushes for installing ground wires
6.3.8. Extra plastic zip ties > 6” long
6.3.9. Extra NPT sealant (i.e., Kleinn Air Horn Juice, Teflon tape, etc.)
6.3.10. Touch-up paint for frame/chassis/body (i.e., primer or black epoxy)
6.3.11. Typical cleanup supplies
End of Section

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7. Parts List
7.1. Before Starting, Review Parts List
Unpackage and organize Kit across a large work area and verify all parts are included, as listed below.
Contact Kleinn support if any questions arise.
7.1.1. Review pre-packaged Kit items (i.e., K1, K2, etc.)
7.1.2. Review Air Fittings and Tubing (i.e., F1, F2, etc.)
7.1.3. Review Wiring and Accessories (i.e., E1, E2, etc.)
7.1.4. Review Bolt-On Mounting Brackets (i.e., M1, M2, etc.)
7.1.5. Review Hardware/Fasteners (i.e., H1, H2, etc.)
7.1.6. Review Add-On Accessories (i.e., X1, X2, etc.)
7.1.7. Familiarize yourself with how parts assemble
7.2. Pre-Packaged Electro-Mechanical Kit Items
NOTE: Items in this section come in their own packages and may include additional items inside package
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
K1
1
SD17OBA-6450
Includes Air Compressor, Air
Tank, Brackets, Hardware,
Electrical, etc.
K2
1
730
(734STD ONLY)
730 Series Horn Kit, with included
solenoid/valve, and 1/2” Air
Tubing, 20 ft. long
K2
1
230
(230STD ONLY)
230 Series Horn Kit, with included
solenoid/valve, and 1/4” Air
Tubing, 20 ft. long

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7.3. Air Fittings and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
F1
1
51238L
3/8” NPT X 1/2” Compression
Fitting, 90 Deg Elbow
F2
1
53814R
(230STD ONLY)
3/8” NPT FEMALE X 1/4” NPT
Reducer Fitting
F3
2
51414L
(230STD ONLY)
1/4" NPT X 1/4" TUBE FITTING,
MALE 90 DEG. ELBOW
F4
1
KLEINN AIR HORN
JUICE
THREAD SEALENT FOR NPT
FITTINGS

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7.4. Electrical Small Components and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
E1
1
SD17-STD WIRE KIT
ELECTRICAL WIRE, CONNECTORS,
AND ZIPTIES
•PURPLE (18 GA.) –20 FT
•BLACK (12 GA.) –2 FT
E2
1
SD17-STD LOOM
PACK
WIRE LOOM, CORRUGATED AND
SPLIT
•1/8" X 20 FT
•1/4”X 5FT
•1/2" X 5FT
E3
1
320
TERMINATOR –NICKEL PLATED
REMOTE HORN BUTTON
7.5. Bolt-On Mounting Brackets & Special Hardware
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
M1
1
SD17-304
SPARE TIRE HORN BRACKET, CUT
& FORMED
M2
2
SD17-306
(734STD ONLY)
DUAL TRUMPET SUPPORT
BRACKET, CUT & FORMED

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7.6. Hardware, Fasteners and Soft Parts
NOTE: Pictures only indicative, not to scale and may not represent exact item
ITEM
QTY.
DESCRIPTION
WHERE USED
PICTURE
H1
4
(5/16"-18 X 1.00" LONG)
RIBBED NECK CARRIAGE BOLT,
GRADE 2, ZINC-PLATED
HORN BRACKET MOUNTING (4)
H2
12
(5/16”ID X 1.5" OD)
FLAT WASHER, FENDER, ZINC-
PLATED
HORN BRACKET MOUNTING
(12)
H3
4
(5/16" ID X 0.88" OD)
FLAT WASHER, USS, ZINC-
PLATED
HORN BRACKET MOUNTING (4)
H3
4
(5/16")
LOCK WASHER, SPLIT, ZINC-
PLATED
HORN BRACKET MOUNTING (4)
H4
4
(5/16"-18)
HEX NUT, GRADE 2, ZINC-
PLATED
HORN BRACKET MOUNTING (4)
7.7. Add-On Accessories
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
X1
-
-
-
End of Section

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8. Bench Assembly
Complete following steps off vehicle to facilitate final installation.
8.1. Disassemble Trumpets from Air Horn Drivers
NOTE: This step is performed to facilitate installation on Vehicle of Air Horn sub-assembly, specifically in
connecting Air Tubing, Wiring, and Horn Ore Supports (734STD only). It also enables installer to choose
orientation of small, medium, large Trumpets when re-installing them (i.e. order from left to right).
This step may be omitted if desired, especially on 230STD.
8.1.1. Remove Air Horn sub-assembly from packaging; Air Tubing and Hardware will be used later.
8.1.2. Disassemble Trumpets from Air Horn Drivers by firmly grasping Trumpet around Metal/Chrome Collar and
twisting counter-clockwise, as shown below. If necessary, use pliers with rag or soft material over jaw.
8.1.3. If necessary, clamp sub-assembly to a bench or place in a Vise using soft jaws to facilitate removing
Trumpets
Figure 3 –Removing Trumpets from Air Horn Drivers, Exploded View
K2 –DRIVERS
GRASP HERE

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9. On-Vehicle Mechanical Assembly
Complete following steps on-vehicle using a lift, vehicle ramps, or other safe lifting method.
DANGER: Follows all manufacturer’s instructions for safely lifting vehicle; reference owner’s manual.
9.1. Remove Spare Tire Lift Mechanism
9.1.1. Remove Spare Tire cable lock from Frame (see “1A381”in below image).
9.1.2. Locate Plastic Guide Tube going into Spare Tire Lift Mechanism body (see “1A433”in below image).
9.1.3. Using pry bars or large flat blade screwdrivers, expand end of tube and pull to remove rearward.
NOTE: to completely remove plastic tube from vehicle, it may be required to remove rear bumper, or use
a saw to cut tube and remove in multiple pieces. Otherwise, secure in place with Zip Ties, or similar.
Figure 4 –Exploded view of Spare Tire Mechanism from Ford Parts (2017 F-250/F-350 shown)
Pry open at End
Plastic Tube

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9.1.4. Remove two (2) OE Bolts holding Lift Mechanism to Crossmember (see “HS1”in above image), then twist
Mechanism counterclockwise to remove from Crossmember and lift out of Vehicle. Retain all parts for
future use, if desired.
Figure 5 –Underbody view of Spare Tire Mechanism and Crossmember (2017 F-250 shown)
Remove two (2)
bolts

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9.2. Install Air Horn Bracket (SD17-304)
9.2.1. Using Hardware #H1, H2, H3, H4, & H5 install Brackets onto Spare Tire Crossmember, as shown below. It
is recommended to apply medium-strength Loctite to Bolts and final torque to 75 in-lbs.
NOTE: Initially install Large Bracket -304 using only two (2) bolts, to facilitate alignment with other bolts.
Then insert remaining hardware into front are rear slots, from top down into Bracket
Figure 6 –Underbody view of Crossmember with Mounting Holes and Bolts installed (2017 F-250 shown)
Figure 7 –Installing SD17-304 Bracket (Exploded view shown)
Front Slot
FRONT
Insert these 2
Bolts first
Two (2) Holes
Rear Slot
H2 (12)
H1 (4)
H3 (4)
H4 (4)
M1
H5 (4)
Crossmember
between Fender
Washers & Bracket
75 in-lbs