Kleinn Air Horns RNGR-102-1/220 Installation Manual Download

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RNGR-102-1/220

INSTALLATION MANUAL

REV: IR 02/15/2022

PO Box 91278 Tucson, AZ 85752

Phone: (520) 579-1531

Web:

https://www.kleinn.com

Summary of Contents for RNGR-102-1/220

Page 2: ...ble of Contents REV IR 02 15 2022 2 RNGR 102 1 220 Installation Operation Manual This digital PDF is interactive Please save ink and paper Open interactive manual using Adobe Reader on PC Mac and smart devices ...

Page 3: ...ion s 8 4 2 Install Process Outline 10 4 3 Approximate Installation Time 11 5 List of Tools Supplies 12 5 1 Standard Tool List Required 12 5 2 Special Tool List Recommended 12 5 3 Shop Consumables List Recommended 12 6 Parts List 13 6 1 Review Parts List 13 6 2 Pre Packaged Kit Items 13 6 3 Air Fittings Related Items 14 6 4 Electrical Components Related Items 15 6 5 Mounting Brackets Special Hardw...

Page 4: ...y Fuse Diagram for Air Horn System 26 9 2 Disconnect Vehicle Battery s 27 9 3 Connect Wires to Fuse Relay 27 9 4 Install Horn Button 27 9 5 Connect Pressure Switch 28 9 6 Connect Air Compressor 28 9 7 Connect Air Horn Solenoid s 28 9 8 Secure Wiring to Vehicle 28 10 Final Steps Testing 29 10 1 Reconnect Vehicle Battery s 29 10 2 Test Air Compressor 29 10 3 Test Train Horns 29 10 4 Test Quick Conne...

Page 5: ...n 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 the installation testing and operation of following SKU part num...

Page 6: ...ou have all 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 ...

Page 7: ...e been found to be incompatible with the designed kit No incompatible configurations are known at this time 3 3 Aftermarket Product Compatibility This kit has been designed to work with the following aftermarket products Power running boards steps Fix running boards steps This kit has not been designed to work with the following aftermarket products No incompatibilities are known at this time NOTE...

Page 8: ...f the following components located on vehicle as follows ITEM DESCRIPTION VEHICLE LOCATION APROX INSTALL TIME 1 6275RC Air Compressor 102 1 KIT 6450RC Air Compressor 220 KIT Passenger side rear bed pocket 1 hr 2 1 5 Gal Air Tank Driver side rear bed pocket 2 hrs 3 102 1 Air Horns 102 1 KIT 220 Air Horns 220 KIT Under cab 2 hrs Figure 1 Isometric Overlay of Kit Locations ...

Page 9: ...s REV IR 02 15 2022 9 RNGR 102 1 220 Installation Operation Manual Figure 2 Under Vehicle View Compressor Behind Rear Wheel Well Passenger Side Figure 3 Under Vehicle View Horns Under Driver Side Seating Area 220 Horns Shown ...

Page 10: ...le air filter to air compressor 4 Attach compressor to compressor bracket 5 Attach air tank to tank brackets 6 Assemble horn DRIVERS to horn bracket ON VEHICLE MECHANICAL ASSEMBLY SECTION 9 7 Mount compressor bracket to vehicle 8 Mount tank brackets to vehicle 9 Mount horn bracket to vehicle 10 Attach horn trumpets to the horn drivers 220KIT ONLY 11 Connect pneumatic components route air tubing ON...

Page 11: ...on Time RNGR 102 1 220 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 5 hrs END OF SECTION ...

Page 12: ...ded 1 Power hand grinder pneumatic grinder with cut off wheel or hacksaw 2 10 100 ft lbs torque wrench 3 20 150 in lbs torque wrench 4 Multi meter for 12V DC electrical systems or equivalent 5 12V DC test Light or equivalent 6 Trim panel tool for removing wiring and body clips when needed 5 3 Shop Consumables List Recommended 1 Quality electrical tape 2 Dielectric grease for electrical connections...

Page 13: ...dd On Accessories X_ 7 Familiarize yourself with how the parts assemble 6 2 Pre Packaged 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 6275RC 102 1KIT ONLY 6275RC Compressor Kit with included hardware and remote air supply line K1 1 6450RC 220KIT 6450RC Compressor Kit with included hardw...

Page 14: ... for 102 1KIT ONLY Adapter 1 4 NPT 1 4 NPTF Elbow F4 1 54440 220KIT ONLY Adapter T 1 4 NPT 1 4 NPTF 1 4 NPTF F5 1 51414F Comp Fitting 1 4 NPTF 1 4 F6 1 52175 Safety Valve 1 4 NPT 175PSI F7 1 52835 Drain 1 4 NPT F8 1 2151 1 4 NPT Pressure Switch F9 1 Air Horn Juice Thread Sealant for NPT Fittings F10 1 25014 1 1 4 Airline x 12 F11 1 25014 2 1 4 Airline x 25 F12 1 1302 220KIT ONLY Remote Quick Conne...

Page 15: ...peration Manual 6 4 Electrical Components Related Items ITEM QTY PART NUMBER DESCRIPTION PICTURE C1 1 320 Terminator Nickel Plated Remote Horn Button C2 1 WIRE KIT Full Wire Kit with electrical connectors and zip ties C3 1 Loom Pack Wire Loom Corrugated Split X 30 ft X 12 ft ...

Page 16: ...NGR 102 1 220 Installation Operation Manual 6 5 Mounting Brackets Special Hardware ITEM QTY PART NUMBER DESCRIPTION PICTURE H1 1 RNGR 100 Compressor Bracket H2 1 RNGR 201 Tank Bracket Front H3 1 RNGR 202 Tank Bracket Rear H4 1 RNGR 300 Horn Bracket ...

Page 17: ...6 7 16 14 x 1 25 Hex Bolt Fully Threaded Zinc Plated H2 2 7 16 x 922 OD Washer SAE 7 16 H3 10 7 16 x 1 256 OD Washer USS 7 16 H4 6 7 16 Split Lock washer 7 16 H5 6 7 16 14 Nut 7 16 14 H6 2 1 4 20 x 1 102 1KIT ONLY Button head screw H7 6 1 4 x OD 102 1KIT ONLY Washer SAE 1 4 H8 2 1 4 Split 102 1KIT ONLY Lock washer 1 4 H9 2 1 4 20 102 1KIT ONLY Nut 1 4 20 NOTE Hardware included with kit components ...

Page 18: ... H9 1 4 20 Horn Mounting 102 1KIT 6 7 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 illustrations ensure they are oriented correctly Click here to view fittings...

Page 19: ... remote quick connect 12 220KIT ONLY 7 2 Assemble Air Tank to Tank Brackets When assembling the following components using bolts nuts washers and lock washers follow the stacking order shown below Figure 6 Hardware Assembly Order 1 Use H1 H3 H4 H5 to attach the tank brackets to the tank as shown Figure 7 Air Tank Bracket Assembly Exploded View 7 3 Assemble Air Filter to Air Compressor 1 Remove the...

Page 20: ...s included in the compressor package NOTE The air filter tubing is rigid and may be difficult to route without kinks or install over fittings If necessary use a heat source heat gun or similar at a safe distance to make tubing pliable for routing installation on fittings Figure 8 Remote Air Intake w Tubing For Compressor 7 4 Assemble Air Compressor to Compressor Bracket 1 Apply Air Horn Juice to t...

Page 21: ...mpet near the metal collar with one hand the horn driver with the other hand Twist counter clockwise to unscrew the trumpet from the driver as shown below Figure 10 Trumpet Driver Separation 7 6 Assemble Air Horn Driver to Horn Bracket 102KIT ONLY Use the hardware included with the horns along with H6 H7 H8 H9 to attach the horns to the bracket as shown 220KIT ONLY Use the hardware included with t...

Page 22: ...all Air Tank on Vehicle 1 Locate the highlighted mounting points circled REF below Figure in the pocket behind the driver side rear wheel well 2 Remove the hardware indicated by the arrows set aside This hardware will be reused Figure 12 Air Tank Install Location 3 Lift the air tank with brackets attached up over the flange with the slot The bracket should rest on top of this flange Attach the bra...

Page 23: ...vehicle Circled below 2 Remove the hardware indicated by the arrows set aside to be reused Figure 14 Air Compressor Install Location 3 Lift the air compressor with bracket attached up over the flange with the slot The bracket should rest on top of this flange Attach the bracket to the mounting points reusing the OEM hardware along with H1 H2 H3 H4 H5 as shown below Figure 15 Air Compressor Install...

Page 24: ...the hardware indicated by the arrows Retain this hardware to be reused for installation of the horn bracket Figure 16 Horn Bracket Install Location 3 Attach the bracket to the mounting points reusing the OEM hardware as shown below Figure 17 Horn Bracket Installation 102 1 220 4 Reattach the horn trumpets to the drivers as shown Short trumpet closer to driver side 220KIT ONLY Figure 18 Trumpets In...

Page 25: ... skip this section 8 4 Route Air Hose and Install Remote Quick Connect Coupler 1 Route airline as desired from compressor to the tank from the tank to the horns and to the remote quick connect coupler 2 Mount the remote quick connect coupler as desired using the hardware and bracket provided as shown below Figure 19 Remote Quick Connect Coupler Assembly END OF SECTION ...

Page 26: ... all recommended safety precautions for working on vehicle s electrical system consult vehicle owner s manual for further instruction 9 1 Relay Fuse Diagram for Air Horn System Figure 20 Suggested Ignition Relay Diagram for Air Horn System PRESSURE SWITCH either wire can go to Relay or Ignition AIR HORN SOLENOID either wire can be PWR or GND ...

Page 27: ...wer wire by cutting the loop in fuse holder and connecting supplied Ring terminal to one end and butt connector on the other end CAUTION Do not install fuse until all electrical connections are final 9 4 Install Horn Button 1 Find a suitable location for the horn button i e in dash center console etc Verify location has at least 1 of clearance behind for terminal connectors Mark location for drill...

Page 28: ...air tank and connect to the pressure switch per wiring diagram NOTE Either pressure switch wire can be connected to relay or ignition 9 6 Connect Air Compressor 1 Route wiring as desired to the air compressor and connect per wiring diagram 9 7 Connect Air Horn Solenoid s 1 Route wiring as desired to the air horns and connect to the solenoid s per wiring diagram NOTE Either air solenoid wire can be...

Page 29: ... to run and shut off automatically i e air tank is full 2 Verify all tubing and electrical wires are securely fastened to the vehicle brackets or kit parts If necessary use extra zip ties to hold tubing and wire in place 3 Ensure all nearby persons have adequate hearing protection and provide courtesy warning to neighbors or others in vicinity WARNING NEVER operate train horns with ears close to t...

Page 30: ... during recommended intervals 1 Yearly or every 12 000 miles verify all mounting fasteners are properly torqued Applying witness marks across fasteners and mounting parts is good practice to quickly ensure fasteners have not moved 2 Yearly or every 12 000 miles inspect OE wiring tubing cables etc where kit parts may touch to verify no abrasion or rubbing 3 Yearly or every 12 000 miles remove all r...

Page 31: ...formation Thank you for purchasing RNGR 102 1 220 OBA If you experience any unexpected problems during installation or have problems with any part please contact Kleinn support END OF MANUAL Kleinn Air Horns 2021 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web https www kleinn com ...

Page 32: ...o Table of Contents REV IR 02 15 2022 32 RNGR 102 1 220 Installation Operation Manual 14 Record of Revisions Date Revision Description Author 10 28 2021 BETA Beta Manual AG 02 15 2022 IR Initial Revision AG ...

Page 33: ...MENT IS DESIGNED TO BE VIEWED PRINTED AT 100 OR 1 1 SCALE IF PRINTING THIS PAGE PRINT USING ACTUAL SIZE OR 100 SCALE ITEM QTY SCALE IMAGE H1 6 H2 2 H3 10 H4 6 H5 6 ITEM QTY SCALE IMAGE H6 2 H7 6 H8 2 H9 2 2 15 2022 RNGR SCALE_H COMPUTER GENERATED BILL OF MATERIALS HARDWARE SCALE IMAGES RANGER RNGR 102 1 220 HARDWARE ...

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