Kleinn USTL-230 Manuel utilisateur
USTL-230/734
INSTALLATION MANUAL
REV: C (6/25/2021)
© Kleinn Air Horns 2021, All Rights Reserved
PO Box 91278 Tucson, AZ 85752
Phone: (520) 579-1531
Web: https://www.kleinn.com
USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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REV: C (6/25/2021)
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USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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REV: C (6/25/2021)
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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
USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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REV: C (6/25/2021)
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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
USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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REV: C (6/25/2021)
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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
Go to Table of Contents
REV: C (6/25/2021)
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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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REV: C (6/25/2021)
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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
USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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REV: C (6/25/2021)
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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
USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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REV: C (6/25/2021)
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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
USTL-230/734
Kleinn Air Horns
INSTALLATION MANUAL
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REV: C (6/25/2021)
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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
Ce manuel convient aux modèles suivants
1
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