Klenn Air Horns RAMHD-230KIT User manual

RAMHD-230/734KIT
INSTALLATION MANUAL
© Kleinn Air Horns 2018, All rights reserved.
PO Box 91278 Tucson, AZ 85752
Phone: [phone]
Web: www.Kleinn.com
REV: BETA (2/19/2018)

RAMHD-230/734KIT
Installation and Operation Manual
Go to Table of Contents PG 1/41 REV: BETA (2/19/2018)
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RAMHD-230/734KIT
Installation and Operation Manual
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Table of Contents
1. How to Use this Manual .................................................................................................................................... 4
1.1. Interactive Manual using Adobe Reader ................................................................................................... 4
1.2. Your Kit Part Number and this Manual ..................................................................................................... 4
1.3. Illustration/Photo Details and Orientation................................................................................................ 4
2. Safety First ......................................................................................................................................................... 5
3. Application Chart............................................................................................................................................... 6
3.1. 100% Direct Bolt-On Vehicle List ............................................................................................................... 6
3.2. **Excluded Vehicles .................................................................................................................................. 6
3.3. Aftermarket Product Compatibility ........................................................................................................... 6
4. Kit Installation Overview ................................................................................................................................... 7
4.1. Approximate Installation Time .................................................................................................................. 8
4.2. ***Quick Install Outline............................................................................................................................. 9
5. List of Tools and Supplies ................................................................................................................................ 10
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 Related Items ................................................................................................................. 12
6.3. Electrical Small Components and Related Items ..................................................................................... 14
6.4. Bolt-On Brackets and Hardware/Fasteners............................................................................................. 14
7. Bench Assembly Steps ..................................................................................................................................... 16
7.1 Unpack and Layout Kit Parts.................................................................................................................... 16
7.2 Disassemble Train Horn Kit...................................................................................................................... 16
7.3 Mount Medium and Large Horn Drivers to Bracket................................................................................ 18
7.4 Mount Small Horn Driver to Bracket ....................................................................................................... 19
7.5 Mount Air Tank to Bracket ...................................................................................................................... 21
8. On-Vehicle Mechanical Assembly Steps.......................................................................................................... 23
8.1 Large-Medium Horn Assembly Installation ............................................................................................. 23
8.2 Small Horn Assembly Installation ............................................................................................................ 25
8.3 Air Tank Assembly Installation ................................................................................................................ 28
8.4 Compressor and Bracket Installation ...................................................................................................... 30

RAMHD-230/734KIT
Installation and Operation Manual
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9. On Vehicle Air Line Installation ....................................................................................................................... 33
10. On-Vehicle Electrical Installation................................................................................................................. 36
10.1. Disconnect Vehicle Battery(s).............................................................................................................. 36
10.2. Attach 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
11.1. Test Air Compressor ............................................................................................................................ 38
11.2. Test Train Horns................................................................................................................................... 38
11.3. Test Quick Connect Coupler ................................................................................................................ 38
12. General Operation of Kit ............................................................................................................................. 39
12.1. Compressor Operation ........................................................................................................................ 39
12.2. Horn Operation.................................................................................................................................... 39
13. Routine Maintenance .................................................................................................................................. 40
14. Warranty Information ................................................................................................................................. 41

RAMHD-230/734KIT
Installation and Operation Manual
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1. How 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
•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
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1.2. Your Kit Part Number and 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 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 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 this 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.
FRONT

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Installation and Operation 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
3.1. 100% Direct Bolt-On Vehicle List
RAMHD-230/734KIT is a 100% direct bolt-on aftermarket product for DODGE 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
2014-2018
RAM 2500
2WD, 4WD
ALL
Crew Cab (short
bed**), Mega Cab
ALL
2014-2018
RAM 3500
2WD, 4WD,
DUALIE
ALL
Crew Cab (short
bed**), Mega Cab
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
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 listed
Kit may be adapted to these vehicles, with vehicle modification:
1. Small Horn Bracket
Drill mounting holes in vehicle chassis at approximate location shown in instructions
2. Compressor Bracket
Drill mounting holes in vehicle chassis at approximate location shown in instructions
CAUTION: All vehicle modifications are at discretion of end-user/installer; this manual does NOT
provide instruction, or encourage such modification. Contact Kleinn sales for more information.
3.3. Aftermarket 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-230/734KIT consists of the following major components, located on vehicle per following pictures and
chart
ITEM
DESCRIPTION
PICTURE
MOUNTING
LOCATION
APPROX.
INSTALL TIME
1
230/730 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
230/730 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
6350RC/6450RC 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 (734KIT Shown)
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 (734KIT Shown)
Passenger Side View –2014 Ram 2500 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 mechanic, auto enthusiast, or technician installing a Kleinn Bolt-On kit for first time, a
professional installation job with setup and testing of final product, is estimated to take:
•8-12 Hours
1
2
3
4

RAMHD-230/734KIT
Installation and Operation Manual
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4.2. ***Quick Install Outline
For person(s) with experience installing Kleinn bolt-on kits, RAMHD-230/734KIT can be installed in an order
similar to below:
1. Route wiring, install Relay, and Horn Switch
2. Disassemble 230/730 Horn Kit (i.e., separate drivers from trumpets and horn mounting plate)
3. Assemble 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 Assembly to Frame; install Horn Trumpets
8. Mount Small Horn Bracket Assembly to Frame; install Horn Trumpet
9. Mount Air Tank Bracket Assembly to Frame
10. Mount Air Compressor Bracket to Frame and Mount Air Compressor to Bracket
11. Route Air Tubing, Quick Connect Coupler, Air Compressor filter, and connect all Pneumatic components
12. Connect wiring to all components
13. Test System and adjust, as needed