HornBlasters HK-S4-540D User Manual

HORNBLASTERS

Five Gallon Dual Conductor’s Special

Installation Manual

HornBlasters

Five Gallon Dual Conductor’s Special

Support Line: [phone]

Fax Line: [phone]

[e-mail]

www.hornblasters.com/support

Installation Guide

Before Getting Started

Read over the entire instruction guide before you begin your installation.

Kit Contents:

• HornBlasters Conductor’s Horns

• Two ViAir 400C Air Compressor Pump

• ViAir Weather-proof Pressure Switch

• Firestone 5 Gallon 7 Port Air Tank

• Electric Solenoid Valve

• Fittings, Air Line, Wiring Kit, Relays, Fuse Holder, Replacement Air Filters

IMPORTANT: This complete train horn kit uses 12 volt DC components. Only install this kit

with a 12 volt DC power source.

Important Safety Instructions

CAUTION: To prevent the risk of electrical shock or electrocution:

• Do not disassemble any electrical components of this horn kit (air compressor, air valve, pressure switch).
Do not attempt repairs or modifications of any component. Please refer to qualified service agencies for
all service and repairs.

• Do not operate any component where it can fall or be submerged into water or any kind of liquid.

• Do not reach for any component that has fallen or been submerged into water or any kind of liquid.

• Use the included components with 12 volt DC systems only.

• Do not leave the air system unattended during use.

WARNING: To prevent injury:

• Never allow children to operate the compressor or air horn. Use close supervision when operating this
equipment near children.

• The air compressor will become very HOT during and immediately after operation. Do not touch any part
of this compressor with your bare hands during or immediately after use.

• Do not use this product near open flames or explosive materials or where aerosol products are being used.

• Do not operate this product where oxygen is being administered.

• Do not pump anything other than atmospheric air.

• Never use this product while sleepy or drowsy.

• Do not use any tools or attachments with the supplied air source unit without first determining maximum

air pressure for that tool or attachment.

• Never point any air nozzle or air sprayer toward another person or any part of your body.

• The included air compressor is equipped with an automatic reset thermal protector and can automatically

restart after the thermal protector resets. Always cut off power source when thermal protector becomes
activated.

• Use only in well ventilated areas.

• Do not sound the air horn(s) in close proximity to another person’s or your own ear(s).

• Do not fill the included air tank above 150 PSI. Doing so may result in death or serious injury.

Safety During Installation

• Disconnect the ground of your battery before beginning your installation.

• Use eye protection when operating drills.

• Take your time and do not rush your installation.

1

Installing Your Train Horn Kit

Planning Your Installation

This is the most important step in your installation.

• Plan out the location of each component before starting your installation.

• Make sure you have enough air line and wire to install the syst em before beginning the installation.

• Make sure mounting locations are secure and void of debris.

• Try to keep the supply wire to the compressor as short as possible. Wires lose voltage over distance

therefore shorter wires will result in better performance.

• Mount your air compressor in a location that is as cool as possible and away from heat sources. This will
make your compressor run cooler and last longer.

• Your air compressor must be mounted upright or horizontally but never upside down to allow the
compressor to cool properly. To increase performance make sure the compressor is mounted upright.

• Your air compressor should be mounted above the tank. Failure to mount the unit in this position will
allow any condensation buildup to drain back in to the compressor and foul its compon ents.

• Teflon tape or a locking compound should be used on every fitting in your air system to prevent air leaks.

• Air valves can be mounted in every direction but are recommended to be mounted vertically with the pilot

housing above the valve body.

• Use the supplied 12 gauge wire or thicker (lower gauge #) wire to power your air compressor.

Recommended Tools

• 3/8” Long Socket (Horn Front Mount)

• 1/2” Long Socket (Horn Rear Mount)

• 9/16” Wrench (1/4 NPT Fittings)

• 7/8” Wrench (1/2 NPT Fittings)

• 8mm Wrench or Socket (Air Compressor Mounting)

• 16mm Wrench (Metric 1/4 NPT Fittings)

• 22mm Wrench (Metric 1/2 NPT Fittings)

• Drill (With 3/16” and 7/16” Bits)

• Wire Cutter/Stripper

• Tubing Cutter/Razor

• Eye Protection

I. Installing Your HornBlasters Train Horns

Locate an area for your horns that is dry and free from debris. The horns can be mounted in any direction and
still be heard from all around. The horns should not be mounted where they will be completely submerged or will
receive any kind of impact. Horns may be mounted directly to your vehicle, on a medium such as grommet strips
(plumber’s strap), sheet metal or any sort of custom bracket. Note that air line will be running to each horns
rear mount.

1. Location a secure, dry, safe position for your horns.

2. Drill a 3/16” hole for the front mount of each horn and a 7/16” hole for each rear mount.

3. Secure the horn using the supplied mounting hardware.

II. Installing Your Air Compressor Pumps

Locate a flat and secure installation area that will remain free of dust, dirt and debris (your compressors
performance is directly affected by air quality). Try to keep the distance of the unit from the battery to a
minimum to keep your compressor running at maximum performance. Follow the following steps for each
compressor.

1. Disconnect the ground cable from the vehicle’s battery.

2. Position the unit in the desired location and secure it using the supplied mounting hardware (8mm).

3. Remove the orange plug in the compressor’s inlet and install the remot ely mountable air intake assembly.
Using the included 3/8” OD air line and fittings you may relocate the air filter up to six feet away from the
air compressor.

2

III. Installing Your Air Tank

Locate a secure area close to your air compressor to mount your air tank. The leader hose of the compressor
should be able to reach an available port on the air tank with some slack.

1. Position the tank in its desired location and secure it using standard mounting hardware.

IV. Installing Your Air Tubing & Air Valve

Before cutting any air tubing make sure to double check your measurements. Make sure to cut equal lengths of
air line to connect each horn to the splitter manifold or the horns may sound at different times. We recommend
cutting your lengths with at least an extra inch per line just to be safe. Compression fittings use ferrules (olives)
that should be used only once. The air valve should connect to the center
When threading any fittings make sure to use Teflon tape or lock-tight to prevent air leaks.
The air valve may be mounted in any direction but it is preferred that it is mounted vertically.

IMPORTANT: Do not rotate or remove the inline check valve in the compressor’s leader hose. Do ing so will

damage its seals and will result in damage to your air compressor and voiding of your warranty.

IMPORTANT: Do not make any kinks in your air line. Doing so will disrupt air flow and is irreversible.

Air Compressors to Tank (Repeat For Each):

[Air Compressor] » [1/4” Leader Hose] » [1/2 to 1/4 NPT Reducer Bushing] » [1/2 NPT F Port] » [Air Tank]

1. Locate a free 1/2 NPT port on your air tank and install a 1/2 to 1/4 NPT reducer bushing using Teflon tape
across the threads.

2. Carefully connect the air compressor leader hose to reducer bushing using Teflon tape on the threading.
When installing the leader hose DO NOT

3. Locate a secure location to mount the leader hose using the bracket provided. Avoid locations where the
leader hose may become tangled with wires and other hoses.

a. When mounting the bracket drill a hole with a 3/16” drill bit and push the self-anchoring hose

bracket into the hole. Route the leader hose through the hose bracket and secure by pressing the
bracket clamp into the locker position.

Pressure Switch in to Tank:

[Air Tank] » [1/2 NPT to 1/8 NPT Reducer Bushing] » [Pressure Switch Unit]

1. Install the 1/2 to 1/8 NPT reducing bushing into an available port on the air tank using Teflon tape on the
threading.

2. Install the pressure switch unit into the reducer bushing again using Teflon tape on the threading.

Air Horns to Tank:

[Air Tank] » [1/2 to 1/4 NPT Reducer Bushing] » [5/16” to 1/4 NPT M Fitting] » [5/16” Line] »

[5/16” to 1/4 NPT M Fitting] » [Air Valve] » [5/16” to 1/4 NPT M Fitting] » [5/16” Line] »
[5/16” 5-point Splitter Fitting] » [5/16” Line] » [5/16” to 1/8 NPT M Fitting] »
[1/8 NPT F Elbow Fitting] » [Rear Horn Mount]

1. Plan out the fittings’ placement out before you begin and make sure you understand the correct order.

2. Make sure that your tank is empty of air and that the compressor is not running during installation.

3. Start by cutting equal lengths of 5/16” tubing to run from each horn to the 5-point manifold fitting.

4. Install the air line carefully using two wrenches for each compression fitting. Use one wrench to hold the
body of the fitting stationary and another to tighten the compression nut.

5. After plumbing the horns to their manifold fitting, measure and plumb one length of 5/16” tubing from the
center fitting of the manifold to the outlet of the air valve. If the valve has a directional arrow on its body
the arrow starts with the inlet and points out the outlet; the arrow should point towards your horns.

6. Next connect your air valve’s inlet port to your air tank using 5/16” air line using the 5/16” Straight to 1/4
NPT M fittings.

Drain Cock in Tank:

1. Install the drain cock in the 1/4 NPT port on your air tank. If the drain cock has compound on its threads
it is unnecessary to use Teflon tape on the threads.

Extra Ports in Tank:

1. Install the supplied three 1/2 NPT plugs in the remaining 1/2 NPT ports using Teflon tape on the threads.

move the inline check valve located just above the swivel fitting.

fitting of the 5-point splitter fitting.

3

V. Wiring Your Valve & Air Compressor

Your train horn kit will use two completely independent circuits. One circuit will connect your horn trigger (push­button intermittent switch, or toggled factory button) to your electric solenoid valve. The other circuit will
connect your accessory trigger (ignition wire, accessory wire) to your air source kit.

Valve Wiring Flow Chart (Circuit 1)

[Horn Trigger] » [Air Valve] » [Ground]

Air Source Pressure Switch Wiring Flow Chart (Circuit 2)

[Accessory Trigger] » [(Small Red) Pressure Switch (Black)] » [Ground]
[12V DC Source] » [(Large Red) Pressure Switch (White)] » [(Pin 86) Relay (Ping 85)] » [Ground]

Air Source Compressor Wiring Flow Chart (Circuit 3)

[12V DC Source] » [60A Inline Fuse] » [(Pin 30) Relay (Pin 87/87a)] » [(Red) Compressor (Black)] » [Ground]

Circuit 1

1. Begin by wiring your horn trigger.

a. If you are intending to use your factory horn switch, start by locating the load wire of the horn

button (positive when horn button is depressed in a standard vehicle) and wiring it to the included
toggle switch (any side).

b. If you are going to use a push button switch (intermittent toggle switch) wire a fused (5A) wire

from any 12 volt source desired (battery) to your switch (any side).

2. Next wire your switch to any pole (red preferred) of your air valve.

3. Wire the other side (black preferred) of the air valve to ground.

4. Test your circuit by activating your trigger and listening for a quiet “click” sound from the valve.

Circuit 2

1. Locate an accessory line in your vehicle

2. Wire your accessory line to your pressure switch using the small red wire (Trigger).

3. Ground your pressure switch using the small back wire (Ground).

4. Locate an additional accessory line and wire it using an inline fuse (20A) to your pressure switch using the
large red wire (12V DC Source).

5. Connect the pressure switch to the relays using the large white wire (Load) from the pressure switch and
pin 86 of each relay.

6. Connect pin 85 of each relay to ground.

Circuit 3

1. Locate an accessory line capable of a 60A load and wire it to your heavy duty 60A fuse holder.

2. Connect your fuse holder to pin 30 on each relay.

3. Now wire each relay’s pin 87 (or 87a) to the load wire of its corresponding compressor (large red wire).
(Use one relay per compressor)

4. Your air compressor system will now turn on automatically when power is on (key is in “Accessory” or
“On” position and automatically turn itself off upon reaching destination.

You’re Done!

It’s time to test your horns! Send in your install photos to us for a chance to be featured on our website!

4

Maintenance & Tips

Disconnect electrical components and drain your air system before performing maintenance.

General Air Horn System Maintenance

• Check your air horns for debris when appropriate and at least once a month and clean when necessary.

• Drain your air system at least once a month to remove any condensation buildup on the inside of your air

tank.

• Make sure your air compressor is clean and free from debris at all times.

• Periodically change your two stage air filter on your compressor.

Tips

• Make sure your engine is running when your air compressors are in use to insure proper voltage and
prevent damage to your system.

• Do not run your compressor above its maximum rated working pressure. Doing so will not only v oid your
warranty but may also damage your compressor.

• The air horns are pre-tuned to a locomotive chord and to their loudest possible tone. Do not adjust the
tuning screw on the horns. Doing so will void your wa rranty and may damage the horns if maladjusted.

Troubleshooting

Problem Possible Cause(s) Corrective Action

Air horn will not
sound.

Horn tone changes
when sounded.

Excessive moisture in
horn or safety
discharge.

Compressor will not
run.

Thermal overload
protector cuts out
repeatedly.
Excessive knocking or
rattling.

Tank pressure drops
when compressor
shuts off.

Compressor runs
continuously and air
flow lower than
normal.

Compressor runs
continuously causing
safety valve (if
equipped) to open.

1. No pressure in air tank.

2. No power or toggle switch in ‘Off’ position.

3. Blown fuse.

4. Loose connections or bad ground in air valve circuit
(circuit 1).

1. A side fitting was used to connect the air source
(line from valve) to the 5-point splitter manifold.

2. Air line connecting the horns is not of equal length.

1. Excessive water in air tank.

2. Compressor is exposed to high humidity.

1. No power or toggle switch in ‘Off’ position.

2. Blown fuse.

3. Motor overheat.

4. Faulty pressure switch.

1. Lack of proper ventilation/ambient temperature too
high.

2. Compressor valves failed.

1. Loose mounting bolts.

2. Worn bearing on eccentric or motor shaft.

3. Cylinder or piston ring is worn.

1. Loose drain cock.

2. Air valve or check valve is leak ing.

3. Loose connections.

4. Defective safety valve.

1. Excessive air usage.

2. Loose connections.

3. Worn piston ring or inlet valve.

4. Clogged air filter element.

1. Faulty pressure switch.

2. Defective safety valve.

1. Check that air tank is pressurized.

2. Make sure all toggle switches are on.

3. Disconnect electrical components and replace fuse.

4. Check that all electrical circuits are secure and not
corroded.

1. Check that air source (line coming from valve) is
entering the center fitting of the 5-point splitter
manifold.

2. Check that the air line connecting each ho rn to the
5-point splitter manifold is of equal length.

1. Depressurize tank using safety, then drain tank.
Tilt the tank to drain moisture and drain more
frequently.

2. Move the compressor to an area with less humidity.

1. Make sure all toggle switches are on.

2. Disconnect compressor from power and replace
fuse (20A).

3. Let compressor cool off for about 30 minutes for
thermal overload switch to reset.

4. Replace pressure switch.

1. Move compressor to a well ventilated area or an
area with a lower ambient temperature.

2. Replace air compressor.

1. Tighten bolts.

2. Replace compressor.

3. Replace compressor.

1. Tighten drain cock.

2. Replace air valve or check valve.

3. Check all air connections with soap and water
solution and tighten as necessary.

4. Replace safety valve.

1. Decrease air usage.

2. Check all connections with soap and water solution
and tighten as necessary.

3. Replace compressor.

4. Replace air filter element.

1. Replace pressure switch.

2. Replace safety valve.

5

Photograph & Media Submission Guidelines

Send in your installation photographs and any other media for a chance to be featured on our website!

General Photograph Submission Guidelines

• Please submit clean, concise photographs. Make sure your subject is clearly visible and in focus.

• You may submit any digital image format either via email at [e-mail], or via digital media

(CD, DVD, etc).

• Make sure to include some kind of personal information with your submission. We would love to be able
to contact you and thank you.

Installation Gallery Submission Guidelines

• Please take at least one photo of each of the major components of your installation (horns, compressor,
tank, valve, switches, etc).

• Don’t forget to send us some shots of your vehicle too! If we can’t tell what the install is on, we probably
won’t post it.

• Include as much installation information as possible.

o Who installed the system and when was it installed?
o How long did it take?
o What are the year, model, and style of your vehicle?
o If you took your system to a shop, would you recommend the shop to others?
o Do you have any comments or tips about the installation?
o Anything else you want to tell us. We appreciate your feedback!

• Optionally include a little personal information:

o Your name (if you would like your full name to be displayed, you have to let us know!)
o Your State or Country, or even city/town if you would like. (This’ll give you better visibility.)
o How old were you when you had this kit installed?

• Remember, the more photos the better! We’ll only pick out the best ones to post.

General Video Submission Guidelines

• We accept all kinds of media. Please provide us with the highest quality media to prevent video
degradation.

• We can read all formats of video. We recommend using either the default your camera records with; or if
you are compressing the video, we recommend using AVI containers and an MPEG codec. We recommend
against

• You may submit any digital image format either via email at [e-mail], or via digital media
(CD, DVD, etc).

• Make sure to include some kind of personal information with your submission. We would love to be able
to contact you and thank you!

*Windows, Windows Media, Real, Real Media, Apple, and QuickTime are all registered trademarks and copyright
of their respective owners.

using any kind of Windows Media*, Real Media*, or Apple QuickTime* formats.

6

HORNBLASTERS.COM

5 Gallon Dual Conductor’s Special Installation Diagram

12V Battery

To Tank

Air Compressor

Ground (Black)

Load (Red)

+-

12V Fused

30

85 86

87/87a

30

85 86

87/87a

Load (Red)

60A Fuse

(Fused) Positive

Power Source (Red)

Compressor Load

(White)

Port Plug

AIR TANK

Toggle Switch

Run this wire to an ignition wire (this is a wire that
is only powered when the key is turned to the on
position). This will insure that the air compressor
will not run when the car is turned off and drain
your batteries.

Ignition Wire

Trigger/Switch Positive
(Small Red)

Pressure

Switch

Ground (Black)

Port Plug

Air Compressor

HORNBLASTERS

HORNBLASTERS

HORNBLASTERS

HORNBLASTERS

Ground (Black)

5/16” Air Line

5/16” Air Line

5/16” Air Line

Drain Cock

5/16” Air Line

Power
(Red or Black)

Ground (Black)

5/16” Air Line

Hornblasters, Inc.
4532 W. Kennedy Blvd #233
Tampa, FL 33609-2042

Phone: [phone]
Fax: [phone]
email: [e-mail]