HornBlasters systems, including the Shocker XL 540 and Conductor’s Special 127H/228H, provide users with the ability to install train horns on various vehicles. Proper installation, as outlined in the provided documentation, is crucial for system longevity and safe operation. This article details the components, installation procedures, and maintenance recommendations based on official HornBlasters manuals and resources.
System Components
HornBlasters kits contain a variety of components necessary for a complete installation. The specific contents vary depending on the model, but common elements include: horns, an air source (compressor and tank), air lines, wiring harnesses, pressure switches, relays, and mounting hardware.
The Shocker XL 540 kit includes a pressure switch with relay, two 1/2” PTC to 1/2” NPT fittings, a 10-12 gauge Scotch Lock, a HornBlasters gauge, four 5/16” PTC to 1/8” NPT elbows, and an 18-22 gauge Scotch Lock. The Conductor’s Special 127H/228H kit includes a 1/2" electric solenoid valve, an air source kit, ear plugs, HornBlasters Shocker XL horns, an airline cutter, 17’ of 1/2” airline, a HornBlasters universal wiring kit, and various wrenches and bits for installation. Additional components, such as air tanks and valves, are available for separate purchase.
Installation Locations
The documentation recommends different installation locations based on vehicle type. For cars, sedans, and SUVs, the trunk is suggested as an ideal location for the compressor and tank, as it protects the components from the weather. For trucks, the toolbox is a suitable location, but it should not be used as a grounding point. Alternatively, mounting the compressor/tank in the bed of the truck (if covered) or behind the seats are also viable options.
Regardless of the location, it is important to select an area for the horns that is dry and free from debris. Horns can be mounted in any direction without affecting audibility.
Plumbing and Air Line Connections
Proper plumbing is essential for a functional air system. The air valve inlet port should be connected to the air tank using 1/2” air line and 1/2” M NPT to 1/2” PTC fittings. It is recommended to use a side or top port on the tank to prevent condensation from entering the air valve.
When connecting air lines, it is crucial to ensure they are fully seated over the compression fittings before tightening the nut. If the line is not fully seated, it can slip off the fitting even with the nut tightened. Air lines should be cut cleanly to ensure a secure connection. A liquid test can be used to identify leaks; if bubbles appear, fittings may need to be tightened or more Teflon tape applied to the threads.
Electrical Wiring
The Conductor’s Special 127H/228H kit includes a wiring diagram. The system utilizes a relay to control the compressor. When the switch is flipped on, the relay activates, allowing the compressor to run. It is critical to turn the switch off when the vehicle is not in use to prevent the compressor from running overnight and draining the battery. The wiring diagram illustrates a 30A fuse that should be installed. The documentation specifically instructs to cut the fuse in half at the center point.
The universal wiring kit provides the necessary components for connecting the system to the vehicle’s electrical system. Users should exercise caution when working with electrical components and ensure the parking brake is engaged before working under the vehicle.
Air Gauge Installation
The HornBlasters air gauge can be installed into an available 1/2” port on the air tank. Teflon tape or pipe sealant should be applied to the threading of the 1/2” to 1/4” NPT F bushing. The air pressure gauge should be mounted on the side or top of the tank to prevent condensation from entering the gauge.
Maintenance and Troubleshooting
Regular maintenance is recommended to ensure the longevity of the HornBlasters system. This includes changing filters and draining moisture from the tank on a regular basis.
Troubleshooting steps include inspecting mounting hardware to ensure all components are securely fastened. If horns sound muffled, check that each air line is secure in the elbow fittings. If leaks are present, tighten fittings or reapply Teflon tape. Re-cutting and re-seating air lines can resolve connection issues. If issues persist, contacting HornBlasters support at (877)-209-8179 or [email protected] is advised.
Safety Precautions
The documentation emphasizes several safety precautions. Users should wear eye protection when operating drills or other power tools during installation. The parking brake should be engaged before working underneath the vehicle. The system should not be wired without a fuse holder. The compressor should not be allowed to run when the vehicle is off.
Available Resources
HornBlasters provides a variety of resources to assist with installation and maintenance. These include instruction manuals, wiring diagrams, installation galleries, and a help center. Additional resources, such as spare tire delete instructions and a train horn forum, are also available on the HornBlasters website. The website also offers a comprehensive catalog of components, including air lines, air tanks, compressors, and fittings.
Conclusion
Installing a HornBlasters train horn system requires careful attention to detail and adherence to the provided instructions. Proper component selection, plumbing, electrical wiring, and maintenance are crucial for optimal performance and system longevity. By following the guidelines outlined in the official HornBlasters documentation, users can successfully install and enjoy their train horn system.