Kleinn Air Horns GMTRK-3 Install Manual Download

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GMTRK-3

INSTALL GUIDE

REV: A (08/24/2022)

PO Box 91278 Tucson, AZ 85752

Phone: (520) 579-1531

Web:

https://www.kleinn.com

This Install Guide Replaces the GMTRK-1 Installation Manual

Summary of Contents for GMTRK-3

Page 1: ...3 INSTALL GUIDE REV A 08 24 2022 Kleinn Air Horns 2021 All Rights Reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web https www kleinn com This Install Guide Replaces the GMTRK 1 Installation Manual ...

Page 2: ... Recommended 8 4 3 Shop Consumables List Recommended 8 5 Parts List 9 5 1 Primary Kit Components 9 5 2 Pneumatic Components 9 5 3 Electrical Components 10 5 4 Mounting Brackets 10 5 5 Hardware 11 6 Bench Assembly Air Tank Fittings 13 6 1 Tank Fittings 2007 2013 Trucks 14 6 2 Tank Fittings 2014 2018 Trucks 15 6 3 Tank Fittings 2007 2014 SUV s 16 6 4 Tank Fittings 2015 2020 SUV s 17 7 Bench Assembly...

Page 3: ... Assembly Air Horns 27 8 1 Air Horns 2015 to 2020 SUV s 28 8 2 Air Horns All Other Vehicles 29 9 On Vehicle Installation 30 9 1 Tank Compressor Installation 30 9 2 Horn Bracket Installation 32 9 3 Final Connections 34 9 3 1 General Connections Plumbing 34 9 3 2 System Pre Test 34 10 Testing 35 10 1 Test Air Compressor 35 10 2 Test Train Horns 35 11 General Operation 36 11 1 Compressor Operation 36...

Page 4: ...with any questions Installation of this kit requires moderate mechanical aptitude seek professional help if you re not competent using hand tools in tight uncomfortable spaces and around possibly 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 hand protect...

Page 5: ...air based on preference 2 2 Excluded Vehicles The following vehicles have been found to be incompatible with the designed kit Any 2007 Classic Model is incompatible with this kit 2 3 Aftermarket Product Compatibility NOTE Before installing this product on a vehicle with any aftermarket parts attached in regions shown in this manual thoroughly review this manual to verify necessary mounting points ...

Page 6: ... of the following components located on vehicle as follows Item No Component Vehicle Location Install Time APPROXIMATE 1 Compressor Auxiliary Battery Tray 1 Hour 2 1 Gal Air Tank 3 Model 220 Dual Air Horns Behind front bumper in between tow hooks 1 Hour Figure 1 Component Locations Figure 2 Kit Installed Vehicle Configuration 1 Figure 3 Kit Installed Vehicle Configuration 2 ...

Page 7: ...roximate Installation Time This kit is a multi faceted product consisting of mechanical electrical and pneumatic components For a typical home mechanic auto enthusiast or technician installing this kit for first time a professional installation job with setup and testing of final product is estimated to take 2 4 Hours END OF SECTION ...

Page 8: ...ppers 5 Wire crimpers 6 Tubing cutter 7 Torque wrench in lbs ft lbs 4 2 Special Tool List Recommended 1 Heat gun 2 Retrieval tools magnetic gripping 3 Multimeter 12V DC test light or equivalent 4 Trim panel tools 5 Universal joint socket adapters 6 Short handle combination wrenches 4 3 Shop Consumables List Recommended 1 Quality electrical tape 2 Heat shrink tubing for electrical connections 3 Rem...

Page 9: ... Components NOTE Items in this section come in their own packages and MAY include additional items inside package Item No Qty Part Number Description Picture 1 1 6270RC 130 PSI Air Compressor 2 1 6270RT 1 0 Gal Air Tank 5 NPT Ports 3 1 220 Model 220 Dual Train Horn 5 2 Pneumatic Components Item No Qty Part Number Description Picture 4 1 51414NPTL M NPT to F NPT Elbow Fitting 5 1 52155 155 PSI Safe...

Page 10: ...ir Tubing 10 12 ft 25014 Black Air Tubing OD 11 1 JUICE Kleinn Air Horn Juice Thread Sealant 5 3 Electrical Components Item No Qty Part Number Description Picture 12 1 318 The Detonator Pushbutton Switch 13 1 N A Complete Wire Kit 5 4 Mounting Brackets Item No Qty Part Number Description Picture 14 1 N A Battery Tray Bracket 15 1 N A Compressor Relocation Bracket ...

Page 11: ...5 Hardware Item No Qty Description Picture H1 2 7 16 14 1 Long Square Neck Carriage Bolt H2 2 5 8 1 25 OD Washer H3 2 7 16 Split Lock Washer H4 2 7 16 14 Hex Nut H5 4 M8 Split Lock Washer H6 4 M8 Flat Washer H7 3 M6x1 60mm Long Hex Head Bolt H8 3 M8 x 24mm OD Fender Washer H9 2 M10x1 5 45mm Long Hex Bolt H10 2 M10 Flat Washer ...

Page 12: ...laces the GMTRK 1 Installation Manual REV B 09 07 2022 12 H11 2 20 0 5 Long Socket Head Cap Screw H12 Horn Mounting Hardware Assorted H13 Compressor Mounting Hardware Assorted Included inside Horn Box Included inside Compressor Box END OF SECTION ...

Page 13: ...he air tank Apply thread sealant as needed secure fittings per the below instructions Equivalents may be used Apply two drops of Item 13 JUICE to each male pipe thread before installation Hand tighten each fitting then further tighten to turn as necessary to match the fitting orientation shown in the applicable figure Use the configuration that is specific to your vehicle Trucks SUV s 2007 2013 20...

Page 14: ...ittings 2007 2013 Trucks Use the below images to match the alignment of the fittings You may install the fittings in any orientation to accommodate your desired routing of the air tubing compressor hose and electrical wiring Figure 5 Tank Fitting Installation 07 13 Trucks Figure 6 Tank Profile Views 07 13 Trucks ...

Page 15: ...tch the alignment of the fittings You may align the fittings in any orientation to accommodate your desired routing of the air tubing compressor hose and electrical wiring It is recommended to install Item No 6 later to facilitate the installation of the battery tray bracket Figure 7 Tank Fitting Installation 14 18 Trucks Figure 8 Tank Profile Views 14 18 Trucks ...

Page 16: ...tch the alignment of the fittings You may align the fittings in any orientation to accommodate your desired routing of the air tubing compressor hose and electrical wiring It is recommended to install Item No 6 later to facilitate the installation of the battery tray bracket Figure 9 Tank Fitting Installation 07 14 SUV s Figure 10 Tank Profile Views 07 14 SUV s ...

Page 17: ...tch the alignment of the fittings You may align the fittings in any orientation to accommodate your desired routing of the air tubing compressor hose and electrical wiring It is recommended to install Item No 6 later to facilitate the installation of the battery tray bracket Figure 11 Tank Fitting Installation 15 20 SUV s Figure 12 Tank Profile Views 15 20 SUV s ...

Page 18: ...e following steps off vehicle Install the Tank Compressor onto the main bracket s as shown in this section Fully secure the parts to the bracket Plumb the Compressor to the air tank hookup the air tubing to the air tank Use the configuration that is specific to your vehicle 2007 2013 Trucks 2007 2014 SUV s 2014 2018 Trucks 2015 2020 SUV s ...

Page 19: ... 7 1 1 Tank Installation Use hardware H1 H2 H3 H4 to install the tank onto the battery tray bracket as shown below Fully tighten the hardware Figure 13 Tank Installation 07 to 13 Trucks 07 to 14 SUV s 7 1 2 Compressor Installation 1 Use the hardware included in the compressor package to install the compressor onto the battery tray bracket as shown below Fully tighten the hardware Figure 14 Compres...

Page 20: ...ces the GMTRK 1 Installation Manual REV B 09 07 2022 20 2 Connect the leader hose from the compressor to the female fitting on the tank as shown below You may use any alternate routing hookup as needed Figure 15 Compressor Hose Routing Recommended ...

Page 21: ...cket to the compressor relocation bracket 7 2 1 Bracket Assembly Combine the battery tray bracket the compressor relocation bracket as shown below using hardware H11 Fully tighten the hardware Figure 16 Bracket Assembly 2014 to 2018 Trucks 7 2 2 Tank Installation Use hardware H1 H2 H3 H4 to install the tank onto the battery tray bracket as shown below Fully tighten the hardware Figure 17 Tank Inst...

Page 22: ...lly tighten the hardware 2 If fitment issues are present during installation onto the vehicle the BLUE alternate mounting may be explored If using this mounting option one 1 set of the compressor mounting hardware will not be used Figure 18 Compressor Installation 14 to 18 Trucks 3 Connect the leader hose from the compressor to the female fitting on the tank as shown below You may use alternate ro...

Page 23: ... 2020 SUV s Use the below figures to install the tank and compressor to the battery tray bracket to the compressor relocation bracket 7 3 1 Bracket Assembly Combine the battery tray bracket the compressor relocation bracket as shown below using hardware H11 Fully tighten the hardware Figure 20 Bracket Assembly 2015 to 2020 SUV s ...

Page 24: ...lation 15 to 20 SUV s 7 3 3 Compressor Installation 1 Use the hardware included in the compressor package to install the compressor onto the battery tray bracket as shown below in RED Fully tighten the hardware 2 If fitment issues are present during installation onto the vehicle the BLUE alternate mounting may be explored If using this mounting option one 1 set of the compressor mounting hardware ...

Page 25: ...laces the GMTRK 1 Installation Manual REV B 09 07 2022 25 3 Connect the leader hose from the compressor to the female fitting on the tank as shown below You may use alternate routing hookup as needed Figure 23 Compressor Hose Routing Recommended ...

Page 26: ... No 7 90 Compression Fitting A heat gun or equivalent may be used to soften the end of the tubing to facilitate the installation over the barb of the fitting 2 Install the air tubing included with your compressor onto the barbed fitting on the compressor intake 3 Tape cover the exposed ends of the air tubing to prevent debris from entering during kit installation routing END OF SECTION ...

Page 27: ...llowing steps off vehicle using the following instructions Install the Air Horns onto the horn bracket as shown in this section Fully secure the parts to the bracket Plumb the horns together as desired using the included air tubing the appropriate fitting Use the configuration that is specific to your vehicle 2015 2020 SUV s All Other Vehicles ...

Page 28: ...ith hardware H5 H6 to install the air horns to the horn bracket Use the below figures for assembly hardware stacking order Figure 24 Horn Installation 2015 to 2020 SUV s Figure 25 Horn Installation Hardware Exploded View Route trim the included air tubing as desired connect both compression fittings on the horns using Item No 9 Compression T Fitting as the interconnect between the horns ...

Page 29: ...dware H5 H6 to install the air horns to the horn bracket Use the below figures for assembly hardware stacking order Figure 26 Horn Installation All Other Vehicles Figure 27 Horn Installation Hardware Exploded View Route trim the included air tubing as desired connect both compression fittings on the horns using Item No 9 Compression T Fitting as the interconnect between the horns END OF SECTION ...

Page 30: ... compressor onto the auxiliary battery tray Install Horns onto the vehicle Complete the wiring 9 1 Tank Compressor Installation 1 Place the tank compressor assembly onto the auxiliary battery tray and identify three 3 bolt holes that provide the best accessibility Reference the below figures Note the bolts chosen and remove the tank compressor assembly from the auxiliary battery tray ...

Page 31: ...nk Compressor Assembly onto the aux battery tray using hardware H7 H8 to replace the bolts removed from the previous step as shown in the below figure Fully tighten the hardware and torque to OEM specifications Figure 30 Tank Compressor Assembly Installed Red Configuration Left Blue Configuration Right 4 At this time install Item No 6 Pressure Switch if it was not installed previously Be sure to f...

Page 32: ...behind the front bumper with the horns directed to the passenger side as shown in the below figure Figure 31 Horn Bracket Installed Location Behind Front Bumper 1 Remove the front two 2 OEM engine shield bolts The horn bracket will attach to these two points with the circular standoffs contacting the engine shield The below figure illustrates this step Figure 32 Engine Shield Bolt Removal ...

Page 33: ... step The trumpets should be directed towards the passenger side of the vehicle The trumpets may be removed from the horn bases by gripping the chrome collar and twisting counterclockwise This may facilitate the installation of the horn bracket by giving better access to the hardware Figure 33 Horn Bracket Installed Upper Trumpet Removed Shown 3 Fully tighten the hardware and reattach the trumpets...

Page 34: ...d self tapping screw or by another method hard mount the relay to any suitable location which allows the appropriate wiring connections to be made 3 Route and wire the system using the below figure When connecting the horn solenoid wires connect one wire from each solenoid together then connect them to the purple wire Connect the remaining wire from each solenoid to a grounding point Figure 34 Wir...

Page 35: ...e air pressure from system i e slowly open drain valve 6 Disassemble leaky connection re seal and reinstall fittings tubing as needed 10 2 Test Train Horns 1 Allow the air compressor to run and shut off automatically i e air tank is full 2 Ensure all nearby persons have adequate hearing protection and provide courtesy warning to neighbors or others in vicinity WARNING NEVER operate train horns wit...

Page 36: ...rload protector will reset after 30 minutes 3 To prevent discharge of the vehicle s battery and for best performance keep the vehicle s engine running while using the air compressor for any prolonged use 11 2 Horn Operation 1 Allow the air compressor to run until it shuts off automatically i e air tank is full or for at least one minute between horn activations 2 Press the horn button to activate ...

Page 37: ...equently if traveling regularly off road or in winter climates with road salts High pressure washers may damage part finishes and must be used with care 4 Yearly or every 12 000 miles check electrical connections wires and air fittings for abrasion corrosion or other damage Replace damaged components NOTE if system runs continuously or turns on unexpectedly leaks or a poor electrical connection ma...

Page 38: ...formation Thank you for purchasing our Air Horn Kit Shall you experience any unexpected problems during installation or have problems with any part at any time please contact Kleinn support END OF MANUAL Kleinn Air Horns 2021 All rights reserved PO Box 91278 Tucson AZ 85752 Phone 520 579 1531 Web https www kleinn com ...

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