Hornblasters XL 248, XL 240, XL 232, XL 244 User Manual

Shocker XL Installation Manual

232, 240, 244, 248

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.

HornBlasters

Shocker XL
Installation Guide

Before Getting Started

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

Support Line: [phone]

Fax Line: [phone]
[e-mail]

www.hornblasters.com

Kit Contents:

• HornBlasters Shocker Horns

• Viair 325/400/444/480 Air Compressor

• 1/2” Electric Solenoid Valve

• 17’ 1/2” Airline

• 10’ 5/16” Airline

• 2 x 1/2” PTC to 1/2” NPT

• 4 x 5/16” PTC to 1/8“ NPT Elbow

• 1 x 1/2” NPT to 4x 5/16” PTC

• 17’ 10 Gauge Wire

• 17’ 18 Gauge Wire

• 5 x 18-22 Gauge Butt Connector

• 3 x 10-12 Gauge Butt Connector

• 2 x 18-22 Gauge Ring Terminal

• 1 x 10-22 Gauge Ring Terminal

• 1 x 10-22 Gauge Male Quick Disconnect

• 1 x 18-22 Gauge Male Quick Disconnect

• 1 x 10-12 Gauge Scotch Lock

• 1 x 18-22 Gauge Scotch Lock

• 1 x 35 Amp Fuse

• 1 x Inline Fuse Holder

• 1 x Toggle Switch

• 1 x 1/4” 175 PSI Safety Valve

• 1 x 1/2” NPT to 1/4” Reducer

• 1 x 1/4” Drain Cock

• 1 x Pressure Switch w/ Relay

• 1 x HornBlasters Gauge

• 1 x Teflon Tape

• 1 x Horn-Air 2 Gallon Tank

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, 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.

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 airline and wire to install the system 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 source unit 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 source unit must be mounted upright with the compressor above the tank. Failure to mount the unit in this position
will allow any condensation buildup to drain back in to the compressor and harm its components, and also will disrupt the
compressor’s ability to cool.

• 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.

• Use the supplied 10 gauge wire or thicker (lower gauge #) wire to power your air compressor.

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.

We recommend installing our kits in a certain configuration. With the 2 gallon tank, you have two 1/2” ports and four 1/4”
ports. Install the tank in position where one 1/4” port is facing down for the drain cock. From there place the gauge, pressure
switch and safety blow off valve in the remaining three 1/4” ports. For the 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

• 3/8” Long Socket (Horn Front Mount)

• 1/2” Long Socket (Horn Rear Mount)

• 1/2” Wrench

• 9/16” Wrench (1/4” NPT Fittings)

• 7/8” Wrench (1/2” Banjo)

• 10mm Wrench or Socket (Air Source Mounting)

• 12mm Wrench

• Drill (3/16” & 7/16” Bits)

• Wire Cutter/Stripper

• Tubing Cutter/Razor

• Eye and Ear 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. Locate a secure, dry, and 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 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.

2