Kleinn USTL-230 User manual

USTL-230/734
INSTALLATION MANUAL
REV: C (6/25/2021)
© Kleinn Air Horns 2021, All Rights Reserved
PO Box 91278 Tucson, AZ 85752
Phone: [phone]
Web: https://www.kleinn.com

USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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USTL-230/734
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INSTALLATION MANUAL
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Table of Contents
1 How to Use This Manual.......................................................................................................................6
1.1 Interactive Manual Using Adobe Reader......................................................................................6
1.2 Your SKU Number & this Manual..................................................................................................6
1.2.1 USTL-230 or USTL-734 ..........................................................................................................6
1.3 Illustration/Photo Details & Orientation ......................................................................................6
2 Safety First ............................................................................................................................................7
3 Application Chart ..................................................................................................................................8
3.1 Bolt-On Vehicle List.......................................................................................................................8
3.1.1 Full-Size Trucks by Generation..............................................................................................8
3.1.2 Mid-Size Trucks by Generation .............................................................................................9
3.2 Known Fitment Issues.................................................................................................................10
3.2.1 Newer RAM Trucks..............................................................................................................10
3.3 Excluded Vehicles........................................................................................................................11
3.4 Aftermarket Product Compatibility ............................................................................................11
4 Installation Overview ..........................................................................................................................12
4.1 Kit Layout & System Location(s) .................................................................................................12
4.2 Install Process Outline.................................................................................................................13
4.3 Approximate Installation Time....................................................................................................13
5 List of Tools & Supplies .......................................................................................................................14
5.1 Standard Tool List (Required) .....................................................................................................14
5.2 Special Tool List (Recommended)...............................................................................................14
5.3 Shop Consumables List (Recommended)....................................................................................14
6 Parts List..............................................................................................................................................15
6.1 Review Parts List .........................................................................................................................15
6.2 Pre-Packaged Electromechanical Kit Items.................................................................................15
6.3 Air Fittings & Related Items ........................................................................................................16
6.4 Electrical Components & Related Items .....................................................................................17
6.5 Mounting Brackets & Special Hardware.....................................................................................17
6.6 Hardware, Fasteners, & Soft Parts..............................................................................................18
7 Test Fit USTL*......................................................................................................................................19

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8 Bench Assembly..................................................................................................................................20
8.1 Assemble Air Fittings to Air Tank ................................................................................................20
8.2 Assemble Air Filter to Air Compressor........................................................................................21
8.3 Attach Threaded Rod to USTL Structure.....................................................................................21
8.4 Assemble Kit Components to USTL Structure.............................................................................22
8.4.1 Assemble Air Horns to USTL Structure................................................................................22
8.4.2 Assemble Compressor to USTL Structure ...........................................................................22
8.4.3 Assemble Tank to USTL Structure.......................................................................................23
8.4.4 Adhere Rubber to USTL Structure.......................................................................................23
8.4.5 Install Snap-In Caps.............................................................................................................24
8.4.6 Attach Leader Hose to Tank & Route Air to Horns .............................................................24
9 On-Vehicle Mechanical Assembly.......................................................................................................26
9.1 Remove Spare Tire......................................................................................................................26
10 On-Vehicle Electrical Installation....................................................................................................27
10.1 Relay & Fuse Diagram for Air Horn System ................................................................................27
10.2 Disconnect Vehicle Battery(s).....................................................................................................28
10.3 Connect Wires to Fuse & Relay...................................................................................................28
10.4 Install Horn Button......................................................................................................................29
10.5 Connect Pressure Switch.............................................................................................................29
10.6 Connect Air Compressor .............................................................................................................29
10.7 Connect Air Horn Solenoid(s)......................................................................................................29
10.8 Raise USTL Assembly into Final Position.....................................................................................30
10.9 Secure Wiring to Vehicle.............................................................................................................30
11 Final Steps & Testing.......................................................................................................................31
11.1 Reconnect Vehicle Battery(s)......................................................................................................31
11.2 Test Air Compressor....................................................................................................................31
11.3 Test Train Horns..........................................................................................................................31
11.4 Test Quick Connect Coupler........................................................................................................31
12 General Operation ..........................................................................................................................32
12.1 Compressor Operation................................................................................................................32
12.2 Horn Operation...........................................................................................................................32

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13 Routine Maintenance .....................................................................................................................32
14 Warranty Information.....................................................................................................................33
END OF TABLE OF CONTENTS

USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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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
To Download & Install Adobe Reader®
On PC or Mac:
•Visit https://get.adobe.com/reader/otherversions/
On Android/iOS, and Windows devices:
•Visit https://get.adobe.com/reader/otherversions/
1.2 Your SKU Number & this Manual
This manual covers installation, testing, and operation of the following SKU part numbers
1.2.1 USTL-230 or USTL-734
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
1.3 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
FRONT

USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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2Safety First
Read this manual thoroughly before starting installation of this kit. Verify that you have all of the 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

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3.2 Known Fitment Issues
3.2.1 Newer RAM Trucks
Some newer RAM trucks have a U-shaped structure inside the spare tire’s rim that requires
horns to be mounted facing the side of the truck, unless this structure is removed (this piece
is welded on). The USTL will fit over this structure without modification.
Figure 1: RAM Spare Tire Location (2016 2500 Shown)
Figure 2: RAM Spare Tire Location Fitment
Figure 3: RAM Trumpets Passenger Side Installation

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3.3 Excluded Vehicles
The following vehicles have been found to be incompatible with the designed kit:
MODEL YEAR
MODEL
DRIVE
ENGINE
BODY
TRIM
N/A
-
-
-
-
-
3.4 Aftermarket Product Compatibility
This kit has not been designed to work with the following aftermarket products:
•Aftermarket dual exhaust systems
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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4Installation Overview
4.1 Kit Layout & System Location(s)
USTL-230/734 consists of the following components, located on vehicle as follows:
ITEM
DESCRIPTION
VEHICLE LOCATION
MOUNTING METHOD
APROX. INSTALL
TIME
1
Air compressor
Spare Tire Location
Attach to structure.
Winched into place.
2 hours
2
Tank
3
Horns

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4.2 Install Process Outline
For person(s) with experience installing the USTL, a reminder of the install steps is provided below:
UNPACKAGE KIT (SECTION 7)
1. Layout and organize all parts
CONFIGURATION CHECK (SECTION 8)
2. Attach horns to USTL structure
3. Raise USTL into place to check for clearance
BENCH ASSEMBLY (SECTION 9)
4. Assemble horn kit components to USTL structure
ON-VEHICLE MECHANICAL ASSEMBLY (SECTION 10)
5. Lower spare tire
ON-VEHICLE ELECTRICAL ASSEMBLY (SECTION 11)
6. Install relay & fuse, route wiring, and install horn button
7. Connect all electrical items (air horn(s), pressure switch, air compressor)
8. Raise USTL assembly into place
FINAL STEPS (SECTION 12)
9. Test system
4.3 Approximate Installation Time
The USTL-230/734, 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:
•2 hours
END OF SECTION

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5List of Tools & Supplies
5.1 Standard Tool List (Required)
1. Basic mechanic’s 3/8” drive socket sets with extensions
•Inch size sockets (5/16”, 1/2", 9/16”, 5/8”, 3/4”, 13/16”, 7/8”)
2. Basic mechanic’s combination wrenches (box/open-end)
•Inch size wrenches(5/16”, 1/2", 9/16”, 5/8”, 3/4”, 13/16”, 7/8”)
3. Basic mechanic’s Allen wrenches
•Inch size Allens (3/8”)
4. Basic mechanic’s screwdriver set (Philips, Flat Head)
5. Diagonal cutter/wire cutter pliers
6. Wire strippers
7. Wire terminal crimpers
8. Slip-joint pliers
9. Vise grips or locking pliers
10. Utility knife or utility razor blade
5.2 Special Tool List (Recommended)
1. 10-100 ft-lbs. torque wrench
2. Multi-meter for 12V DC electrical systems or equivalent
3. 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. Medium-strength thread-locker (i.e., Blue Loctite® PN 242) or equivalent
5. Low-strength thread-locker (i.e., Purple Loctite® PN 222) or equivalent
6. Black/Clear silicone for drilling holes in body
7. Sandpaper or wire brushes for installing ground wires
8. Extra plastic zip ties > 6” long
9. Extra NPT sealant (i.e., Kleinn Air Horn Juice, Teflon tape, etc.)
10. Touch-up paint for frame/chassis/body (i.e., primer or black epoxy)
11. Typical cleanup supplies
END OF SECTION

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INSTALLATION MANUAL
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6Parts List
6.1 Review Parts List
Unpackage and organize kit across a large work area and verify all parts are included, as listed
below. Contact Kleinn support with any questions.
1. Review pre-packaged kit items (K_)
2. Review Air Fittings and Tubing (F_)
3. Review Wiring and Accessories (E_)
4. Review Bolt-On Mounting Brackets (C_)
5. Review Hardware/Fasteners (H_)
6. Review Add-On Accessories (X_)
7. Familiarize yourself with how the parts assemble
6.2 Pre-Packaged Electromechanical 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
6350RC
(USTL-230 Only)
Air compressor kit, with
included hardware, leader
hose, remote air filter,
connectors, and tubing.
K2
1
6450RC
(USTL-734 Only)
Air compressor kit, with
included hardware, leader
hose, remote air filter,
connectors, and tubing.
K3
1
The Beast 230
(USTL-230 Only)
230 Series Horn Kit, with
included solenoid/valve, and
1/4” Air Tubing, 15 ft. long
K4
1
The Demon 730
(USTL-730 Only)
730 Series Horn Kit, with
included solenoid/valve, and
1/2” Air Tubing, 15 ft. long
K5
1
6350RT
Air tank, 3 gallon, 7-port

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6.3 Air Fittings & Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
F1
1
50040*
Plug, 1/4NPT, External Hex
F3
1
52175
Safety Valve, 175PSI, 1/4NPT
F4
1
52835
Drain, 1/4NPT
F5
2
51414NPTL
Adpt. 1/4NPT-1/4NPTF Elbow
F6
1*
51214L
(USTL-734 ONLY)
Comp. Fit. 1/4NPT-1/2 Elbow
F7
1*
51414L
(USTL-230 ONLY)
Comp. Fit. 1/4NPT-1/4 Elbow
F8
1*
51414L
(Included in 1302L)
Comp. Fit. 1/4NPT-1/4 Elbow
F9
1
51214R
Reducer, 1/2NPT-1/4NPTF
F10
1*
25012
(USTL-734 ONLY)
1/2" AIR TUBING
F11
1
25014
1/4" AIR TUBING

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6.4 Electrical Components & Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
E1
1
2151
PRESSURE SWITCH, 1/4NPT
E2
1
318-BK
Horn Button
E3
1
340
RELAY, 12V, SPDT
6.5 Mounting Brackets & Special Hardware
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
C1
1
USTL
STRUCTURE, SPARE TIRE
MOUNT

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6.6 Hardware, Fasteners, & Soft Parts
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
H1
2
THREADED ROD, 3/8-16 X 16”
H2
8
FLAT WASHER, 3/8”
H3
4
LOCK WASHER, 3/8”
H4
8
NUT, 3/8-16
H5
6
FLAT WASHER, M8
H6
6
NUT, M8-1.25
H7
4
SOCKET-CAP SCREW, 7/16-14 x
1”
H8
8
FLAT WASHER, 7/16”
H9
4
LOCK WASHER, 7/16”
H10
4
NUT, 7/16-14
H11
2
USTL-RUBBER
RUBBER STRIP
H12
4
USTL-CAP
SNAP-IN TUBE CAP
H13
1
C-Channel Rubber
END OF SECTION

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7Test Fit USTL*
*This step is optional, but is recommended if your vehicle is not listed as compatible on the
application chart.
1. Before continuing, temporarily attach the horns to the USTL structure using the supplied
hardware, along with items H5 and H6, in the configuration shown.
Figure 4: Default Horn Config. (734 horns shown)
2. Consult your owner’s manual to lower and remove the spare tire.
If the spare tire is not present, lower the winch.
3. Insert the winch flange through the 3-1/4” opening in the USTL structure.
4. Guide the USTL strucutre into place as it is rasied.
5. Check for clearance with the default configuration. Note adjustments as needed. The
structure may be mounted with horns facing front, rear, passenger’s side, or driver’s side of
the vehicle. This installation guide will show horns facing the front of the vehilce.
6. Lower assembly
7. Optional: Remove horns.
END OF SECTION

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8Bench Assembly
Complete the following steps off of the vehicle to prepare for final installation.
When assembling components using bolts, nuts, washers, and lock washers follow the assembly order
shown below:
Figure 5: Hardware Assembly Order
It is recommended to use a thread locker and a torque wrench when tightening fasteners.
Use the following chart for torque specifications.
Item
Thread Size
Used for
Torque Spec (lb.-ft.)
H4
3/8-16
USTL structure threaded rods
23
H6
5/16-18
Horn mounting
13
H7
1/2-13
Tank mounting
57
-
10-32
Compressor mounting
2.5 (30 lb.-in.)
8.1 Assemble Air Fittings to Air Tank
1. Gather all necessary air fittings and the air tank. Ensure all threads on fittings and inside ports are
clean.
2. Apply two small drops of Kleinn Air Horn Juice to each male pipe thread, before inserting.
3. Attach air fittings to the air tank, per below illustration. Use F1 if you do not wish to connect the
remote air coupler.
Click here to view fittings list
Figure 6: 6350RT with Fittings (734 shown)
4. Hand-tighten each fitting, then further tighten 1/4-1/2 turn using proper sized box-end wrench.

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8.2 Assemble Air Filter to Air Compressor
1. Remove the compressor from its packaging, including hardware and air filter.
2. Review included directions in the compressor package pertaining to the remote air filter. Select
the location on the vehicle where the air filter will be mounted, or if desired, filter housing may be
secured to included structure using zip ties.
3. Pry-open the plastic air filter housing and ensure the foam filter is intalled. Attach fittings for
filter to the end of the air the compressor and filter housing. Follow instructions included in the
compressor package.
NOTE: The air filter tubing is rigid and may be difficult to install over barb fittings. If necessary, use
a hair dryer, candle, or heat gun at a safe distance to soften the end of the air tubing and place
over fitting. Do not bend tubing excessively and cause it to kink. Use even heat if necessary, to
bend tubing sharply.
Figure 7: Air Compressor Remote Air Filter and Tubing (shown without air compressor)
8.3 Attach Threaded Rod to USTL Structure
Repeat the following steps twice, once for each threaded rod (H1) provided.
1. Insert threaded rod halfway through USTL structure.
2. Add hardware in order shown.
Figure 8: Threaded Rod Assembly
3. Insert threaded rod the rest of the way though USTL structure.
4. Add remaining hardware as shown.
5. Center threaded rod on the structure and tighten hardware.
6. Repeat for second threaded rod.
Air Filter Remote
Mounting Flange
Air Tubing w/Fitting
for Remote Mount
Air Filter Housing

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8.4 Assemble Kit Components to USTL Structure
8.4.1 Assemble Air Horns to USTL Structure
1. **NOTE: Trumpet may need to be removed from horn driver to install solenoids.
2. Use the hardware supplied with the air horn kit, along with items H5 and H6, to attach the horns
to the USTL structure. (Supplied horn mounting bar is not used)
Swap horn location(s) and fitting(s) as needed. See Section 8.
Figure 9: Horn Installation (734 horns, default config. shown)
8.4.2 Assemble Compressor to USTL Structure
1. Use the hardware supplied with the compressor to attach the compressor to the USTL structure.
Place the head of the compressor towards the end of the USTL structure with the plate with a
diamond-shape cutout.
Figure 10: Compressor Installation (6450RC shown) (other components hidden for clarity)