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
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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

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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

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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
To install Adobe Reader ®
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On Android, iPhone/iPad, and Windows devices,
•visit https://acrobat.adobe.com/us/en/acrobat/mobile-app.html
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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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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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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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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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

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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

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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
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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6. Parts List
RAMHD-230/734KIT includes all major items listed below
This parts list covers following kit part numbers
1. RAMHD-230KIT (i.e., 230 Train Horns)
2. RAMHD-734KIT (i.e., 730 Train Horns)
6.1. Pre-Packaged Electro-Mechanical Items
NOTE: Items in this section come in their own packages and may include additional items inside package
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
1
1
6350RC
(230KIT ONLY)
6350RC Compressor Kit,
with included hardware,
and remote air supply
line
1
1
6450RC
(734KIT ONLY)
6450RC Compressor Kit,
with included hardware,
and remote air supply
line
2
1
230
(230KIT ONLY)
230 Series Horn Kit, with
included solenoid/valve,
and 1/4” Air Tubing, 12
ft. long
2
1
730
(734KIT-ONLY)
730 Series Horn Kit, with
included solenoid/valve,
and 1/4” Air Tubing, 12
ft. long

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6.2. Air Fittings and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
3
1
6355RT
Air Tank, 6-Port, Narrow
Legs
4
2
51414L
(view location on Air Tank)
1/4” NPT X 1/4”
Compression Fitting, 90
Deg Elbow
5
1
52835
(view location on Air Tank)
1/4” NPT, Drain Valve
6
1
52175
(view location on Air Tank)
1/4” NPT, 175 PSI Safety
Valve
7
1
51214L
(734KIT-ONLY)
(view location on Air Tank)
1/4” NPT X 1/2”
Compression Fitting, 90
Deg Elbow
8
1
51214R
(734KIT-ONLY)
(view location on Air Tank)
1/2” NPT FEMALE X 1/4”
NPT Reducer Fitting
8
1
51412
(230KIT ONLY)
(view location on Air Tank)
1/2” NPT X 1/4”
Compression Fitting

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9
1
2151
(view location on Air Tank)
1/4” NPT Pressure Switch
10
1
51414F
1/4” NPT FEMALE X 1/4”
Compression Fitting
11
2
25014
(230KIT ONLY)
1/4” Air Tubing, 12 ft.
long
11
2
25012
(734KIT ONLY)
1/2” Air Tubing, 12 ft.
long
12
1
1302
Quick Connect Air
Coupler Kit, with
relocation bracket
13
1
INF-1
Inflator Kit, with Air Hose
and Bag
14
1
KLEINN AIR HORN JUICE
Thread Sealant for NPT
Fittings

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6.3. Electrical Small Components and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
15
1
320
Terminator –Nickel
Plated Remote Horn
Button
16
1
WIRE KIT
Full Wire Kit, with
electrical connectors and
zip ties
17
1
¼” WIRE LOOM, 20 ft. Long
1/4” Wire loom for
electrical routing
18
1
1/8” WIRE LOOM, 10 ft. Long
1/8” wire loom for
electrical routing
6.4. Bolt-On Brackets and Hardware/Fasteners
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
19
1
RAMHD HARDWARE
1/2”-13 Bolts, Nuts, and
Washers for bracket
mounting
20
1
4 BOLT TANK HARDWARE
7/16”-14 Bolts, Nuts, and
Washers for tank
mounting

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21
1
HORN SEPARATION
HARDWARE
5/16”-18 Bolts, Nuts, and
Washers for horn
mounting
22
1
RAMHD_HORN-LG_BRKT-
ASSY
Medium-Large Horn
Bracket
23
1
RAMHD_HORN-SM_BRKT
Small Horn Bracket
24
1
RAMHD_TANK_BRKT-ASSY
Air Tank Bracket
25
1
RAMHD_COMPRESSOR_BRKT
Air Compressor Bracket
26
6
RAMHD_WASHER
Washer for Frame Slots

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7. Bench Assembly Steps
Complete following steps off vehicle to facilitate final installation.
7.1 Unpack and Layout Kit Parts
Unpackage RAMHD-230/734KIT and verify all parts are included per above Parts List. Contact Kleinn support if
any questions arise.
It is recommended to layout and organize parts across a large work bench, or table in following order:
1. Review train horn box and included hardware
2. Review air compressor box and included hardware
3. Review air tank box and included hardware
4. Review kit mounting brackets and included hardware
5. Review electrical/air fittings and included wiring and tubing
7.2 Disassemble Train Horn Kit
1. Remove trumpets from drivers and set aside.
a. Starting with largest trumpet, tightly grasp trumpet with both hands and unscrew counter
clockwise; trumpet may be very tight. Repeat on medium trumpet, then small.
i. Drivers are identical and do NOT require marking Small, Medium, Large
b. If necessary, clamp horn mounting plate to rigid table, in vise, or seek help to hold plate.
2. Cut semi-rigid plastic air tubing between horns.
a. Use sharp side/diagonal cutters, or equivalent to safely sever tubing.

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WARNING: tubing is difficult to sever using any type of fixed blade (i.e., knife, razor blade, box
cutter, etc.)
3. Loosen Compression Nuts on center driver and remove horn drivers from mounting plate.
a. Use properly sized socket, or box-end wrench.
b. Horn mounting plate and fasteners will NOT be re-used during installation.
4. Remove cut tubing from fittings.
a. Using slip-joint pliers, or equivalent, pull and twist off tubing connected to compression fittings.
b. Depress collar on quick release fitting with one hand, then twist and pull plastic tube out with
other hand. If necessary, use slip-joint pliers, or equivalent to twist and pull tubing out.
c. For further instruction on properly using quick fittings, reference this SMC Video
d. Discard old tubing.

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7.3 Mount Medium and Large Horn Drivers to Bracket
1. Attach Horn Driver to bracket with Large trumpet and Ore Mount (734KIT Only), per below illustration.
(734KIT Shown)
a. Use Horn Separation Hardware kit
i. Assemble fasteners clean and dry using proper socket and box-end wrench.
b. Do not use Ore Mount Rubber Bushing (included in kit).
Ore Mount (734KIT Only)

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2. Attach Air Solenoid and fitting to Horn Driver with built-in tee and attach to bracket, per below
illustration.
(734KIT Shown)
a. Apply two small drops of Kleinn Air Horn Juice to male pipe threads.
i. Hand-tighten each fitting, then further tighten with wrench 1/4-1/2 turn
ii. Verify that air flow arrow on Solenoid points to horn driver and facing up.
b. Use Horn Separation Hardware kit and hand-tighten fasteners to bracket.
i. Assemble fasteners clean and dry using proper socket and box-end wrench
ii. Final tightening will be completed on vehicle.
7.4 Mount Small Horn Driver to Bracket
1. Attach Small Horn Driver to bracket, per below illustration
a. Use Horn Separation Hardware kit
i. Assemble fasteners clean and dry, and finger tighten; they should be tight enough that
horn driver does not move freely, but can be repositioned with some hand force.
ii. Final tightening will be completed on vehicle.
iii. Observe correct driver orientation, based on specific vehicle.
Solenoid Pre-Attached
(230KIT Only)