Nathan AirChime Installation Manual
Nathan P3, P5, K3LA, K5LA 540 Kit
WARNING: To ensure the longevity of your
system. reading and following these instruc-
tions are recommended. Make sure to change
lters and to drain the moisture from your
tank on a regular basis.
Support Line: +1 (813) 783-8058
HornBlasters
Nathan AirChime
Fax Line: +1 (813) 783-2407
support@hornblasters.com
www.hornblasters.com
Installation Guide
Before Getting Started
Read over the entire instruction guide before you begin your installation.
Kit Contents:
• Nathan AirChime P3, P5, K3LA, K5LA
• Viair 400 12 volt Air Compressor
• HornAir 5 gallon 8 port tank
• SMC 1/2” Electric Solenoid Valve
• Fittings, Air line, Wiring Kit
• HornBlasters 250 PSI Gauge
• HornBlasters 150 PSI Pressure Switch with built in Relay
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 the 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 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.
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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.
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 airline and wire to install the system before beginning the installation.
• Make sure mounting locations are secure and clear 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 components.
• Teflon tape or a locking compound should be used on every fitting in your air system to prevent air leaks; unless a white or
red PTFE paste is already applied.
• Air valves can be mounted in any position but are recommended to be mounted vertically with the pilot housing above
the valve body. Make sure the directional arrow is pointed towards the horns.
• Use the supplied 10 gauge wire or thicker (lower gauge #) wire to power your air compressor.
We recommend installing our kits in a certain configuration. With the 5 gallon tank, you have seven 1/2” ports and one 3 /4”
port. Install the tank in position where one 1/2” port is facing down, then use the 1/2“ to 1/4” reducer bushing fitting for the
drain cock. From there place the gauge, pressure switch and safety blow off valve in three 1/2” ports using the 1/2“ to 1/4”
reducer bushings. For two 1/2” ports, one of them will have the 1/2” to 1/4” female reducer bushing for the compressor (1/2” to
3/8” for the Viair 480c) and the other 1/2” port is for the 1/2” PTC to 1/2” NPT M fitting for the horns.
Recommended Tools
• 1/2” Wrench
• 9/16” Wrench (1/4” NPT Fittings)
• 7/8” Wrench (1/2” NPT Fittings)
• 8mm Wrench or Socket (Air Source Mounting)
• 12mm Wrench
• Drill (3/16” & 7/16” Bits)
• Wire Cutter/Stripper
• Tubing Cutter/Razor
• Eye Protection
I. Installing Your Nathan AirChime Train Horn
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 the center of the horn mainfold.
1. Locate a secure, dry, and safe position for your horns.
2. Install your custom bracket. We recommend welding a piece of sheet metal.
2. Drill holes in your bracket to align with the AirChime manifold.
3. Secure the horn on to the bracket.
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II. Installing Your Air Compressor Pump
Locate a at and secure installation area that will remain free of dust, dirt, and debris (your compressors performance is
directly aected 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 remotely mountable air intake assembly. Using the
included 3/8” OD air line and ttings you may relocate the air lter up to 6 feet away from the air compressor.
4. Only hand tighten the check valve.
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. We recommend cutting your lengths with at
least an extra inch per line just to be safe. Unlike compression ttings, the push to pull connectors can be used multiple times.
When threading any ttings make sure to use Teon tape or lock-tight to prevent air leaks. Some ttings may already have
pipe sealant applied on their threads for your convenience. The air valve may be mounted in any direction but it is preferred
that it is mounted vertically. Your tank has seven 1/2” NPT ports and one 3/4” NPT port.
IMPORTANT: Do not rotate or remove the inline check valve in the compressor’s leader hose. Doing 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 ow and the damage is irreversible.
Air Compressor to Tank:
1. Carefully connect the air compressor leader hose to the 1/2” to 1/4” NPT F Reducer bushing that is located on either end of
the tank using Teon tape or paste on the treading. When installing the leader hose DO NOT move the inline check valve
located just above the swivel tting.
a. If installing a Viair 480c you will use a 1/2“ to 3/8” NPT F Reducer.
2. 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 put 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.
Air Horns to Tank:
to 1/2” PTC Fitting] » [1/2” Air Line] » [1/2” NPT M to 1/2” PTC Fitting] » [Rear Horn Mount]
1. Plan out the ttings placement 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 installing the 1/2“ PTC to the tank.
4. Install the valve in a safe location, preferably closer to the horns. 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.
5. Next install PTC ttings on both open sides of the valve and on the bottom of the horn manifold. Make sure that the lines
are inserted rmly into their sockets. You do not use Teon tape or pipe sealant with the PVC ttings.
6. Now run the air line from your horn manifold to the air tank and cut the length required. Make sure the cut end is at and
the cut is completely perpendicular to the tubing length.
6. Finally install the air line carefully between the horns and the air valve making sure not to damge the PTC ttings.
[Air Compressor] » [1/4” Leader Hose] » [1/2“ to 1/4” NPT F Reducer] » [Air Tank]
[Air Tank] » [1/2” NPT M to 1/2” PTC Fitting] » [1/2” Air Line] » [1/2” NPT M to 1/2” PTC Fitting] » [Air Valve] » [1/2” NPT M
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Drain Cock to Tank:
1. Install the drain cock into the 1/2” port on the bottom of the tank using the 1/2” to 1/4” NPT F bushing. If the drain cock
already has sealant on its threads it is unnecessary to use Teon tape on the threads.
Pressure Switch in to Tank:
1. Install the pressure switch into an available 1/2” port on the air tank using Teon tape or pipe sealant on the threading of the
1/2” to 1/4” NPT F bushing. Make sure to mount the pressure switch on the side or the top of the tank so that condensation
will not be able to drain in to the pressure switch. Hand tighten only, and don't tighten by twisting the box.
Safety Valve in Tank:
1. Install the safety valve into an available 1/2” port on the air tank using Teon tape or pipe sealant on the threading of the
1/2” to 1/4” NPT F bushing. If the safety valve already has sealant on its threads, it is unnecessary to use Teon tape on the
threads. Do not mount on bottom of tank, and do not use as drain.
Air Gauge in Tank:
1. Install the Hornblasters Air Gauge into available 1/2” port on the air tank using Teon tape or pipe sealant on the threading
of the 1/2” to 1/4” NPT F bushing. Make sure to mount the air pressure gauge on the side or the top of the tank so that
condensation will not be able to drain in to the gauge.
Remaining Ports:
1. If you did not purchase any accessories to go along with your Shocker XL kit, you will have one 1/2” port and one 3/4” port
open. The kit comes with two hex plugs to cover these ports. This does give you the option to run air tools, air source
relocation or many other accessories that we sell.
V. Wiring Your Valve & Air Source Unit
Your train horn kit will use two completely independent circuits. One circuit will connect your horn trigger (push-button
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. If you have trouble with wiring, you can nd a wiring diagram of your vehicle on
www.the12volt.com. This can help you locate certain wires to properly and safely install your train horn kit!
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. Wire your switch to any lead of your air valve.
3. Wire the other side 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. Find the accessory line in your vehicle (this is a wire that is only powered when the key is turned to the ‘accessory’ or ‘on’
positions.
2. Using the supplied 18 gauge wire connect the accessory wire to the “BLUE ignition positive wire” from the pressure switch.
3. Ground your pressure switch using the small “BLACK wire” from the pressure switch.
4. Locate your 12v DC power source that is capable of handling a 26 amp load.
5. Run the supplied 10 gauge or bigger wire to the inline fuse holder using the supplied 35 amp fuse. Then connect this to the
“RED fused 12v positive wire” from the pressure switch.
6. Connect the pressure switch to the air compressor using the “WHITE compressor wire” from the pressure switch to the “RED
wire” from the compressor.
7. Ground the other side of your air compressor using the “BLACK wire”.
8. Your compressor system will now turn on automatically when power is on (key is in ‘Accessory’ or ‘On’ position) and
automatically turn itself o upon reaching pressure limits.
You’re Done!
It’s time to test your horns! Share your install photos on our Facebook fanpage at www.facebook.com/hornblasters and don’t
forget to check out www.trainhornforums.com, the largest train horn community on the internet!
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Maintenance & Tips
Disconnect electrical components and drain you 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 every other week, 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 is in use to insure proper voltage and to prevent damage to
your system.
• Do not run your compressor above its maximum rated working pressure. Doing so will not only void you warranty, but may
also damage your compressor.
Troubleshooting
Problem
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 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 4-point banjo manifold.
2. Air line connecting the horns is not of equal length.
1. Excessive water in 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 leaking.
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 4-point banjo manifold.
2. Check that the air line connecting each horn to the
4-point banjo 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 & replace fuse (35A).
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.
Can’t Figure It Out?
No problem! Give us a call at 813-783-8058, or email at support@hornblasters.com and we’ll be more than happy to help you fix your system. Also feel free
to visit our online horn community, www.trainhornforums.com, for more information.
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Photograph & Media Submission Guidelines
Send in your installation photographs and any other media for a chance to be featured on our web site!
General Photograph Submission Guidelines
• Please submit clean, concise photographs. Make sure your subject is clearly visible and in focus.
• You may submit and digital image format either via email at media@hornblasters.com, 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 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.
¤ Who installed the system and when was it installed?
¤ How long did the install take?
¤ What is the year, model, and style of your vehicle?
¤ If you took your system to a shop, would you recommend the shop to others?
¤ Do you have any comments or tips about the installation?
¤ Anything else you want to tell us, we always appreciate your feedback!
• Optionally include a little personal information:
¤ Your name (if you would like your full name to be displayed, you have to let us know!)
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 Xvid, Divx, or a MPEG codec. We recommend AGAINST using any kind of
Windows Media*, Real Media*, or Apple QuickTime* formats.
• You may submit any digital image format either via email at media@hornblasters.com, 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.
Get Involved In The Train Horn Community
No matter what your take is on your new train horn kit, it’s always good to have someone to share your stories with.
Trainhornforums.com is the largest train horn community online and provides a place to share photos of your ride, post
videos, catch up with other train horn and HornBlasters fans, meet other train horn enthusiasts, or even find help with a
complicated question.
Go online to www.trainhornforums.com and sign up today!
Make sure to follow us on all the popular social media! Facebook, Vine, Twitter, Youtube, and Instagram. Show o your
install and tag us in all you photos!
@hornblasters #hornblasters
/hornblasters
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