Klenn Air Horns GMTRK4, Installation Manual

Page 1: ...GMTRK4 INSTALLATION MANUAL Kleinn Air Horns 2020 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web www Kleinn com REV BETA 4 4 2020...

Page 2: ...llation and Operation Manual Go to Table of Contents PG 2 42 REV BETA 4 4 2020 This digital PDF is interactive Please save ink and paper Open interactive manual using Adobe Reader on PC MAC and all sm...

Page 3: ...Electro Mechanical Kit Items 13 7 3 Air Fittings and Related Items 14 7 4 Electrical Small Components and Related Items 15 7 5 Bolt On Mounting Brackets Special Hardware 16 7 6 Hardware Fasteners and...

Page 4: ...ng to Fuse and Relay 38 10 5 Install Horn Button 39 10 6 Connect Pressure Switch 39 10 7 Connect Air Compressor 39 10 8 Connect Air Horn Solenoid s 39 10 9 Secure Wiring to Vehicle 39 11 Final Steps T...

Page 5: ...TRK 4 102 Bolt Plate 2020 Silverado shown 26 Figure 17 Air Tank Compressor Bracket installation Exploded View 27 Figure 18 Air Tank Bracket installed onto OE Rock Guard 2020 Silverado Shown 27 Figure...

Page 6: ...2 2 Your Kit SKU Number and this Manual This manual covers installation testing and operation of following SKU part numbers 2 2 1 GMTRK4 i e 102 Train Horn System NOTE Illustrations and pictures cont...

Page 7: ...sibly rusted and sharp vehicle parts Before starting obtain proper tools required to perform installation correctly adequate lighting eye protection hearing protection for operating train horns and ha...

Page 8: ...echanical Assembly section 4 2 Excluded Vehicles 4 2 1 N A 4 3 Aftermarket Product Compatibility 4 3 1 This kit has been designed to be compatible with following products from leading manufacturers Mo...

Page 9: ...0RC Air Compressor Underbody Driver Side behind Rear Tire inside Bed Side Bracket bolts to Bed Wheel Rock Guard 1 2 Hours 2 6260RT 5 Gal Air Tank Underbody Driver Side behind Rear Tire inside Bed Side...

Page 10: ...0 Figure 2 Under Vehicle View of Air Horn Installed Behind Front Bumper 2020 Silverado Shown Figure 3 Under Vehicle view of Air Tank Installed Behind Driver Bed Side 2020 Silverado Shown Figure 4 Unde...

Page 11: ...tall Air Compressor 9 Remove pull down Engine Shield to gain access to Driver s Frame Mount 10 Install Air Horn sub assembly GMTRK 4 301 w Horn Drivers 11 Connect Air Compressor to Air Tank 12 Connect...

Page 12: ...ded 6 2 1 Power Hand Grinder Air Grinder with Cut Off wheel or Hacksaw 6 2 2 10 100 ft lbs torque wrench 6 2 3 20 150 in lbs torque wrench 6 2 4 Multi Meter for 12V DC electrical systems or equivalent...

Page 13: ...ssories i e E1 E2 etc 7 1 4 Review Bolt On Mounting Brackets i e M1 M2 etc 7 1 5 Review Hardware Fasteners i e H1 H2 etc 7 1 6 Review Add On Accessories i e X1 X2 etc 7 1 7 Familiarize yourself with h...

Page 14: ...on Air Tank F2 1 52145 1 4 NPT 145 PSI SAFETY VALVE view location on Air Tank F3 1 51414L 1 4 NPT X 1 4 TUBE FITTING MALE 90 DEG ELBOW view location on Air Tank F4 2 51414NPTL 1 4 NPT X 1 4 NPT FEMAL...

Page 15: ...STRAIGHT GMTRK4XTREME ONLY F10 1 KLEINN AIR HORN JUICE THREAD SEALENT FOR NPT FITTINGS F11 1 25014 1 1 4 AIR TUBING 18 FT LONG 7 4 Electrical Small Components and Related Items ITEM QTY PART NUMBER D...

Page 16: ...Bolt On Mounting Brackets Special Hardware ITEM QTY PART NUMBER DESCRIPTION PICTURE M1 N R GMTRK 4 101 6450 COMPRESSOR BRACKET CUT FORMED GMTRK4XTREME ONLY M2 1 GMTRK 4 102 TANK COMPRESSOR BOLT PLATE...

Page 17: ...LATED COMPRESSOR TO BRACKET 4 H4 4 10 24 HEX NUT GRADE 2 ZINC PLATED COMPRESSOR TO BRACKET 4 H5 4 5 16 18 X 1 00 LONG SQUARE NECK BOLT GRADE 2 ZINC PLATED TANK BRACKET MOUNTING 2 TANK TO BRACKET 2 H6...

Page 18: ...G 1 TANK BRACKET MOUNTING 3 TANK TO BRACKET 2 H12 1 M8 X 1 25 X 14 5 OFFSET NO SLIP CLIP ON BARREL NUT ZINC PLATED HORN BRACKET MOUNTING 1 H13 1 1 4 ID X 0 63 OD X 1 4 THICK PRESS IN RUBBER GROMMET HO...

Page 19: ...M QTY PART NUMBER DESCRIPTION PICTURE X1 N R 1302L QUICK COUPLER MOUNT KIT BRACKET HARDWARE FITTINGS 1 4 X 15FT AIR TUBING GMTRK4XTREME ONLY X2 N R INF 1 INFLATOR KIT COIL AIR HOSE QUICK CONNECT COUPL...

Page 20: ...Horn Juice to each male pipe thread 8 1 3 Attach Air Fittings to Air Tank per below illustrations ensure they are oriented correctly Click Here to View Fittings List Figure 5 Air Fittings installed o...

Page 21: ...icult to install over Barb Fittings if necessary use Hair Dryer Candle or Heat Gun at a safe distance to soften end of Air Tubing and place over Fitting Do not bend Tubing excessively and cause it to...

Page 22: ...rn Driver to Bracket adjust orientation of Air Horn Fitting as shown below by further tightening Solenoid using an appropriate Wrench If desired Solenoid may be removed threads cleaned and re installe...

Page 23: ...elow Snug tighten H17 fasteners only as Driver may need to be repositioned for proper Trumpet clearance on vehicle Final torque Air Horn included hardware to 37 in lbs NOTE A when installing Air Horn...

Page 24: ...to use a deep socket and rubber mallet to set each Bolt flush This step is required to facilitate installation in Vehicle NOTE if any Bolts fit loosely secure them to back side of Bracket using elect...

Page 25: ...ectly behind rear tire i e OE rock guard as shown below Figure 13 Underbody view of Driver s side Leaf Spring Shackle Bolt 2020 Silverado shown 9 1 2 Using a Hand Grinder Hacksaw or Air Grinder with A...

Page 26: ...as shown below Figure 15 Underbody view of Driver s side mounting holes 2020 Silverado shown 9 2 2 Insert Bolt Plate M2 with Bolts previously pressed in place into Bed Support Brace as shown below Th...

Page 27: ...um strength Loctite to Bolts and final torque to 75 in lbs NOTE Spacer is placed between Bracket and OE Rock Guard Chevys use M3 and GMCs M4 Figure 17 Air Tank Compressor Bracket installation Exploded...

Page 28: ...ce grips or a hand clamp to hold Tank to Bracket to facilitate installing hardware NOTE Insert Air Tank between rear leaf spring shackle and bed side at an angle using a twisting motion and rotating i...

Page 29: ...Tank up down and sideways as needed to obtain clearance all around it from body It is recommended to apply medium strength Loctite to Bolts and final torque to 75 in lbs NOTE Ensure Air Pressure Reli...

Page 30: ...ide at an angle using a twisting motion and rotating it into place over Bolts Use care not to knock out Bolts previously installed or small brass collars in Compressor Feet 9 4 2 Using Hardware H2 H3...

Page 31: ...Juice to male pipe thread on end of Leader Hose and hand tighten use wrench to further tighten 1 4 1 2 Turn CAUTION do NOT over tighten Leader End of Leader Hose onto Fitting over tightening may damag...

Page 32: ...rent than shown Remove OE Bolts as shown below and retain for later Figure 23 Engine Shield Bolts removal 2020 Silverado 5 3L Shown 9 6 2 Once Engine Shield is removed remove OE Clip On frame nut as s...

Page 33: ...Loctite to fasteners and final torque to 75 in lbs NOTE Hardware H12 Clip On Nut must go over BOTH Bracket and Frame First spread Clip On nut open using a pry bar and pliers if having difficulty inst...

Page 34: ...Connect Air Tubing to Air Horn Driver as shown below It is recommended to pre connect Solenoid power PWR wiring and grounds GND at this time Figure 28 Connecting Air Tubing to Air Horn Driver Shown as...

Page 35: ...through front suspension tower as shown below Figure 29 102 Air Horn Tubing Routed through Front Suspension Tower Shown as if installed on Vehicle 9 8 2 Place H13 Rubber Grommet over Air Tubing before...

Page 36: ...pets are firmly tightened by grasping Metal Collar Throat as performed earlier 9 9 2 Reposition Air Horn Driver if needed to ensure at least 1 4 of space exists between them and vehicle especially any...

Page 37: ...ded safety precautions for working on vehicle s electrical system consult vehicle owner s manual for further instruction 10 1 Relay and Fuse Diagram for Air Horn System Figure 32 Suggested Ignition Re...

Page 38: ...0 4 1 Find a suitable location for supplied Fuse and Relay Shown below is an example location under hood next to Battery mounted on firewall Use supplied self tapping screws as necessary Figure 34 Rel...

Page 39: ...Owner s Manual or dealership for further instructions on what wire terminals fuse block location to use and programming required 10 6 Connect Pressure Switch 10 6 1 Route wiring as desired to Air Tank...

Page 40: ...ain Horns 11 3 1 Allow Air Compressor to run and shut off automatically i e Air Tank is full 11 3 2 Verify all tubing and electrical wire is securely fastened to vehicle brackets or kit parts if neces...

Page 41: ...nce during recommended intervals 13 1 Yearly or every 12000 miles verify all mounting fasteners are properly torqued applying witness marks across fasteners and mounting parts is good practice to quic...

Page 42: ...mation Thank you for purchasing GMTRK4 Shall you experience any unexpected problems during installation or have problems with any part at any time please contact Kleinn support End of Technical Manual...