HornBlasters HK-TW-540 User Manual

HORNBLASTERS

Train Whistle Installation Manual

HornBlasters

HornBlasters Train Whistle Package

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Installation Guide

Before Getting Started

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

Kit Contents:

• HornBlasters Exclusive Train Whistle

• 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, Replacement Air Filters

IMPORTANT: This complete train whistle 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 train whistle 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 train whistle. 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 train whistle 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.

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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

• 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

• Wire Cutter/Stripper

• Tubing Cutter/Razor

• Eye Protection

I. Installing Your HornBlasters Train Whistle

Locate an area for your train whistle that is dry and free from debris. The train whistle can be mounted in any
direction and still be heard from all around. The whistle should not be mounted where they will be completely
submerged or will receive any kind of impact. Whistle may be mounted directly to your vehicle, on a medium
such as sheet metal or any sort of custom bracket. Note that air line will be running to the rear of the whistle.

1. Location a secure, dry, safe position for your train whistle.

2. Install your custom bracket. We recommend welding a piece of sheet metal.

3. Drill holes in your bracket to align with the AirChime manifold.

4. Secure the whistle on to the bracket.

II. Installing Your Air Compressor Pump

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.

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.

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