Klenn Air Horns GM1500-734 User manual

GM1500-734
INSTALLATION MANUAL
© Kleinn Air Horns 2020, All rights reserved.
PO Box 91278 Tucson, AZ 85752
Phone: [phone]
Web: www.Kleinn.com
REV: A (5/8/2020)

GM1500-734
Installation and Operation Manual
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Installation and Operation Manual
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Table of Contents
LIST OF FIGURES .........................................................................................................................................................5
1. How to Use this Manual .....................................................................................................................................6
1.1. Interactive Manual using Adobe Reader....................................................................................................6
1.2. Your Kit Part Number and this Manual ......................................................................................................6
1.3. Illustration/Photo Details and Orientation.................................................................................................6
2. Safety First..........................................................................................................................................................7
3. Application Chart................................................................................................................................................8
3.1. 100% Direct Bolt-On Vehicle List................................................................................................................8
3.2. **Excluded Vehicles ...................................................................................................................................8
3.3. Aftermarket Product Compatibility............................................................................................................8
4. Kit Installation Overview ....................................................................................................................................9
4.1. Approximate Installation Time................................................................................................................ 10
4.2. ***Quick Install Outline........................................................................................................................... 10
5. List of Tools and Supplies ................................................................................................................................ 11
5.1. Standard Tool List (Required).................................................................................................................. 11
5.2. Special Tool List (Recommended) ........................................................................................................... 11
5.3. Shop Consumables List (Recommended)................................................................................................ 11
6. Parts List .......................................................................................................................................................... 12
6.2. Pre-Packaged Electro-Mechanical Items................................................................................................. 12
6.3. Air Fittings and Related Items ................................................................................................................. 13
6.4. Electrical Small Components and Related Items..................................................................................... 15
6.5. Bolt-On Mounting Brackets & Special Hardware .................................................................................... 15
6.6. Hardware/Fasteners................................................................................................................................ 17
7. On-Vehicle Electrical Installation..................................................................................................................... 18
7.1. Review suggested Wire Routing for Horn, Air Compressor, and Pressure Switch.................................. 19
7.2. Disconnect Vehicle Battery(s).................................................................................................................. 19
7.3. Attach Relay to Vehicle............................................................................................................................ 20
7.4. Route Wiring and Install Horn Button..................................................................................................... 21
7.5. Connect Relay to Wiring.......................................................................................................................... 21
7.6. Connect Air Horn Solenoid ...................................................................................................................... 21
7.7. Pressure Switch ....................................................................................................................................... 21
8. Bench Assembly Steps..................................................................................................................................... 22

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8.1. Disassemble Pre-Packaged Horn Kit from Box........................................................................................ 22
8.2. Assemble Air Fittings to Air Tank............................................................................................................. 22
8.3. Mount Air Tank and Horn Drivers to Middle Plate Bracket .................................................................... 23
8.4. Connect Air Tubing to Air Tank and Air Horn Drivers.............................................................................. 24
9. On-Vehicle Mechanical Assembly Steps.......................................................................................................... 25
9.1. Air Compressor Installation..................................................................................................................... 25
9.2. Attach Leader Hose Extension to Air Compressor .................................................................................. 27
9.3. Attach Air Compressor Inlet Filter........................................................................................................... 27
9.4. Passenger Side and Driver Side Brackets Installation.............................................................................. 28
9.5. Middle Plate Bracket Assembly Installation............................................................................................ 31
9.6. Connect Air Compressor Leader Hose Extension to Air Tank.................................................................. 32
9.7. Connect Remote Quick Connect Kit to Vehicle ....................................................................................... 32
9.8. Attach Trumpets to Air Horn Drivers....................................................................................................... 33
10. Initial Testing of Kit.......................................................................................................................................... 35
10.1. Reconnect Vehicle Battery(s) .................................................................................................................. 35
10.2. Test Air Compressor ................................................................................................................................ 35
10.3. Test Train Horns....................................................................................................................................... 35
10.4. Test Quick Connect Coupler .................................................................................................................... 35
11. General Operation........................................................................................................................................... 36
11.1. Compressor Operation ............................................................................................................................ 36
11.2. Horn Operation........................................................................................................................................ 36
12. Routine Maintenance...................................................................................................................................... 36
13. Warranty Information ..................................................................................................................................... 37
End of Table of Contents

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Installation and Operation Manual
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LIST OF FIGURES
Figure 1 –Top View Showing Kit Layout (230 Series Horn Kit shown).......................................................................9
Figure 2 –Suggested Ignition Relay Diagram for 230/730 Triple Train Horn.......................................................... 18
Figure 3 –Suggested Wire Routing for Horn, Air Compressor, and Pressure Switch ............................................. 19
Figure 4 –Compressor Mounted, with Wiring Recommendation .......................................................................... 20
Figure 5 –Fitting Locations on Air Tank (Click Here to View Fittings List) .............................................................. 22
Figure 6 –Exploded view of Air Horn Driver and Air Tank onto Middle Plate (Shown with Side Brackets) .......... 23
Figure 7 –Air Horn Drivers connected with Air Tubing example (Shown with Trumpets installed)....................... 24
Figure 8 –GM1500-COMP-BRKT and OE 2nd Battery Tray Mounting Bolts to remove........................................... 25
Figure 9 –Compressor Slots and Bracket Orientation Shown (as installed in vehicle)........................................... 26
Figure 10 –Compressor Carriage Bolts attached and Torqued .............................................................................. 26
Figure 11 –Leader Hose Extension Installed on Compressor Leader Hose ............................................................ 27
Figure 12 –Air Compressor remote Air Filter and Tubing (shown without Air Compressor)................................. 27
Figure 13 –Frame Attachment Points (Passenger Side of frame shown)............................................................... 28
Figure 14 –BOLT-TH Installed in vehicle without OE Tow Hooks (Shown in Passenger Side frame rail) ............... 28
Figure 15 –Bracket Installed to Frame Rail (Shown on Passenger Side frame rail with Tow Hook Bolts).............. 29
Figure 16 –Frame Rail Attachment Points (Driver Side of frame shown)............................................................... 30
Figure 17 –Bracket Installed to Frame Rail (Shown on Driver Side frame rail with Tow Hook Bolts).................... 30
Figure 18 –Underside of Vehicle, with Brackets Mounted..................................................................................... 31
Figure 19 –Air Tank and Air Horn Driver Assembly installed (shown in vehicle) ................................................... 31
Figure 20 –Air Compressor Leader Hose Extension to Air Tank port ..................................................................... 32
Figure 21 –Example of Quick Connect Coupler Installed inside Rear Fender Well................................................ 32
Figure 22 –Installation Orientation of Medium Trumpet (Shown in vehicle on Passenger Side) .......................... 33
Figure 23 –Long and Short Trumpets Installed with Ore Mount (Shown in vehicle on Driver Side) ..................... 34
Figure 24 –Trumpets and Kit Installed (as viewed under vehicle looking forward)............................................... 34
End of Figures

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1. How to Use this Manual
1.1. Interactive Manual using Adobe Reader
It is recommended to open this digital PDF using Adobe Reader ® to take advantage of following key
features:
•Hyperlinks (blue underlined text) allow access to additional content via internet; click/tap to activate
oIncludes Installation Figures and “Figure xx”
•Table of Contents page allows easily navigating this manual; click/tap any section line to go to it
•Bookmarks allow quickly navigating to any section; click/tap
•Zoom IN on pictures by pressing “CTRL and +” at same time on PC, or pinch in on smart devices
•Zoom OUT on pictures by pressing “CTRL and -”at same time on PC, or pinch out on smart devices
To install Adobe Reader ®
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On Android, iPhone/iPad, and Windows devices,
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1.2. Your Kit Part Number and this Manual
This manual covers installation, testing, and operation of following kit part numbers
1.2.1. GM1500-734 (i.e., 730 Train Horns)
NOTE: Illustrations and pictures contained herein may represent only one kit part number.Where
critical differences exist between kits (i.e., different parts, orientation, mounting points, etc.), additional
text, or necessary graphics are provided to minimize confusion.
Parts list explicitly state kit differences with (BOLD TEXT) inside parenthesis, shown below part number.
1.3. Illustration/Photo Details and Orientation
This manual may use digitally created illustrations, and/or actual photos of example vehicle. These graphics may
not include exact items found on your vehicle (i.e., electrical wiring, fuel lines, body panels, etc.). Illustrations
typically will be missing details and are for clarity to show critical mounting locations and orientation on vehicle.
Throughout this manual yellow arrows with text reading “FRONT”, may be
present over illustrations and pictures. These arrows specify direction toward
front of vehicle and provide clarity to how illustration is viewed.
End of Section
FRONT

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2. Safety First
Read manual thoroughly before starting installation of this kit. Verify you have all parts listed and that you
clearly understand this installation procedure. Contact Kleinn technical support for 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 protection to guard against sharp edges and metal burrs,
which may be present on kit parts and vehicle parts.
Throughout this manual the following words may be used; be aware of their meaning and application.
CAUTION: means damage could occur to vehicle, or kit parts during, or after installation
WARNING: means injury could occur to you or others, including damage to vehicle, or kit parts
DANGER: means serious injury or death could occur to you or others during installation
End of Section

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3. Application Chart
3.1. 100% Direct Bolt-On Vehicle List
GM1500-734 is a 100% direct bolt-on aftermarket product for GM vehicles listed in below chart; every effort has
been made to verify correct fitment on these vehicles in their factory, non-modified conditions.
MODEL YR
MODEL
DRIVE
ENGINE
BODY
TRIM
2007.5-2013
SILVERADO
1500
ALL
ALL
ALL
ALL
2014-2015
SILVERADO
1500
N/A**
N/A**
N/A**
N/A**
2016-2018
SILVERADO
1500
ALL
ALL
ALL
ALL
2007.5-2018
SIERRA 1500
ALL
ALL
ALL
ALL
NOTE: All vehicles listed may require drilling holes for ground wires and installing switches, based on
preference of installed switch locations and wire grounding points.
3.2. **Excluded Vehicles
GM1500-734 is NOT compatible with following GM vehicles:
3.2.1. 2014-2015 Silverado 1500 with OEM front bumper, due to interference with Bumper Brackets.
Kit MAY be compatible on these vehicles with aftermarket front bumper.
3.2.2. Any vehicle equipped with GM snow plow package, power take off, or factory installed front
winch mounted behind front bumper
3.3. Aftermarket Product Compatibility
This kit has been designed and tested to be compatible with leading manufacturers of aftermarket truck steps,
such as Amp Research Power Steps ® and all OEM standard and optional steps.
This kit has NOT been designed or tested for use with leading manufacturers of aftermarket front bumpers.
End of Section

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4. Kit Installation Overview
GM1500-734 consists of following sub-systems, located on vehicle, as follows:
ITEM
DESCRIPTION
MOUNTING LOCATION
APPROX.
INSTALL TIME
1
730 Series Large, Medium, and Small
Horn with Air Solenoid
Directly behind front bumper.
Attached to frame rails.
2+ Hours
2
3 Gal. Air Tank
Directly behind front bumper.
Attached to frame rails.
2+ Hours
3
6450RC Air Compressor
Inside Engine Compartment, in
secondary battery tray (Driver’s Side)
1-2 Hours
Figure 1 –Top View Showing Kit Layout (230 Series Horn Kit shown)
2

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4.1. Approximate Installation Time
GM1500-734 is a multi-faceted product consisting of multiple mechanical, electrical, and pneumatic
components.
For a typical home mechanic, auto enthusiast, or technician installing a Kleinn Bolt-On kit for first time, a
professional installation job with setup and testing of final product, is estimated to take:
•6-10 Hours
4.2. ***Quick Install Outline
For person(s) with experience installing Kleinn bolt-on kits, GM1500-734 can be installed in an order similar
to below:
1. Route Wiring, install Relay, and install Horn Switch
2. Disassemble pre-packaged Horn Kit (i.e., unscrew Trumpets and separate Horn Drivers from
mounting bar)
3. Attach Air Fittings to Air Tank
4. Attach Air Tank Assembly to Middle Plate Bracket
5. Attach Air Horn Drivers to Middle Plate Bracket
6. Connect Air Tubing to Air Horn Drivers and Air Tank
7. Install Compressor Bracket and Air Compressor onto 2nd OE Battery Tray
8. Install Compressor Air Filter
9. Install Driver’s Side and Passenger’s Side Brackets to frame
10. Install Middle Plate Assembly to Frame Brackets
11. Connect Air Compressor Leader Hose, Air Tubing and Wiring to Air Horns and Air Tank Fittings
12. Install Quick Connect Coupler and route Air Tubing
13. Install Trumpets into Horn Drivers
14. Test System and adjust, as needed
End of Section

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5. List of Tools and Supplies
5.1. Standard Tool List (Required)
5.1.1. Basic mechanic’s 3/8” drive socket sets with extensions
•Inch Size Sockets (1/4” – 1” Hex)
•Metric Size Sockets (6mm –20mm Hex)
5.1.2. Basic mechanic’s combination wrenches (box/open-end)
•Inch Size Wrenches (1/4” – 1” Hex)
•Metric Size Wrenches (6mm –20mm Hex)
5.1.3. Basic mechanic’s screwdriver set (Philips, Flat Head)
5.1.4. Diagonal Cutter/Wire Cutter Pliers
5.1.5. Wire Strippers
5.1.6. Wire Terminal Crimpers
5.1.7. Slip-Joint Pliers
5.1.8. Utility Knife, or Utility Razor blade
5.1.9. Magnetic retrieval tool
5.2. Special Tool List (Recommended)
5.2.1. 10-100 ft.-lb. torque wrench
5.2.2. 20-150 in.-lb. torque wrench
5.2.3. Multi-Meter for 12V DC electrical systems, or equivalent
5.2.4. 12V DC Test Light, or equivalent
5.2.5. Trim Panel Tool, for removing wiring push pins
5.3. Shop Consumables List (Recommended)
5.3.1. Quality Electrical tape
5.3.2. Di-electric grease for electrical connections
5.3.3. Heat Shrink tubing for electrical connections
5.3.4. Blue Loctite (i.e., Loctite PN 242), or equivalent
5.3.5. Sand Paper, or Wire Brushes for installing ground wires
5.3.6. Extra plastic zip ties > 6” long
5.3.7. Extra NPT sealant (i.e., Kleinn Air Horn Juice, Teflon tape, etc.)
5.3.8. Touch-up paint for frame/chassis
5.3.9. Typical cleanup supplies
End of Section

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6. Parts List
Below Parts List covers following kit part numbers:
6.1.1.GM1500-734 (i.e., 730 Train Horns)
Unpackage and organize Kit across a large work area and verify all parts are included, as listed below. Contact
Kleinn support if any questions arise.
6.1.2.Review pre-packaged items (i.e., train horn box, air compressor, air tank, etc.)
6.1.3.Review Air Fittings and Tubing
6.1.4.Review Wiring and Accessories
6.1.5.Review Bolt-On Mounting Brackets
6.1.6.Review Hardware/Fasteners
6.2. Pre-Packaged Electro-Mechanical Items
NOTE: Items in this section come in their own packages and may include additional items inside package
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
1
1
6450RC
6450RC Compressor Kit,
with included hardware,
and remote air supply
line
2
1
730
730 Series Horn Kit, with
included solenoid/valve,
and 1/2” Air Tubing, 20
ft. long

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6.3. Air Fittings and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
3
1
6350RT
Air Tank, 3.0 Gal., 7-Port
4
1
51212
(view location on Air Tank)
1/2” NPT X 1/2”
Compression Fitting
5
1
52835
(view location on Air Tank)
1/4” NPT, Drain Valve
6
1
52175
(view location on Air Tank)
1/4” NPT, 175 PSI Safety
Valve
7
1
50040
(view location on Air Tank)
1/4” NPT Hex Plug
8
1
51414L
(view location on Air Tank)
1/4” NPT X 1/4”
Compression Fitting, 90
Deg Elbow
9
1
2151
(view location on Air Tank)
1/4” NPT Pressure Switch

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ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
10
1
25012
1/2” Air Tubing, 10 ft.
long
11
1
1302
Quick Connect Air
Coupler Kit, with
relocation bracket
12
1
INF-1
Inflator Kit, with Air Hose
and Bag
13
1
KLEINN AIR HORN JUICE
Thread Sealant for NPT
Fittings
14
1
30103
KLEINN LEADER HOSE
EXTENSION

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6.4. Electrical Small Components and Related Items
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
15
1
320
Terminator –Nickel
Plated Remote Horn
Button
16
1
WIRE KIT
Full Wire Kit, with
electrical connectors and
zip ties
17
1
1/4” WIRE LOOM, 20 ft. Long
1/4” Wire loom for
electrical routing
18
1
1/8” WIRE LOOM, 10 ft. Long
1/8” wire loom for
electrical routing
6.5. Bolt-On Mounting Brackets & Special Hardware
ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
19
2
GM-1500-BOLT-TH
FRAME MOUNT BOLT W/
TAB.
*USED ONLY ON
VEHICLES W/O TOW
HOOKS
20
1
GM1500-BRKT-DR
DRIVER FRAME MOUNT,
MAIN SUPPORT BRACKET

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ITEM
QTY
PART NUMBER
DESCRIPTION
PICTURE
21
1
GM1500-BRKT-PA
PASSENGER FRAME
MOUNT, MAIN SUPPORT
BRACKET
22
1
GM1500-BRKT-MD
MAIN TANK & HORN
MOUNTING BRACKET
23
1
GM1500-COMP-BRKT
COMPRESSOR
MOUNTING BRACKET
(BATTERY TRAY)
24
2
GM1500-SPCR
FRAME MOUNT BOLT
SLEEVE

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6.6. Hardware/Fasteners
ITEM
NO.
SIZE, TYPE
DESCRIPTION
WHERE USED
QTY
H1
5/16”-18 X 1”,
SQUARE NECK BOLT
CARRIAGE BOLT, GRADE 2,
ZINC PLATED
HORN MOUNTING (6)
BRACKET MOUNTING (6)
TANK MOUNTING (4)
16
H2
5/16”-18, LOCK NUT
FLANGED NYLON
LOCKNUT, ZINC PLATED
HORN MOUNTING (6)
BRACKET MOUNTING (6)
TANK MOUNTING (4)
16
H3
5/16”, FLAT
WASHER
SAE FLAT WASHER, ZINC
PLATED
HORN MOUNTING (6)
BRACKET MOUNTING (6)
TANK MOUNTING (4)
16
H4
5/16” X 1.25”,
FENDER WASHER
FENDER WASHER, ZINC
PLATED
TANK MOUNTING (4)
4
H5
1/2” X 2”, FENDER
WASHER
FENDER WASHER, ZINC
PLATED
BRACKET TO FRAME (2)
2
H6
1/2”-13 X 5”, HEX
BOLT
HEX BOLT, GRADE 2, ZINC
PLATED
BRACKET TO FRAME (2)
2
H7
1/2”, FLAT WASHER
SAE FLAT WASHER, ZINC
PLATED
BRACKET TO FRAME (2)
2
H8
1/2”-13, LOCK NUT
FLANGED NYLON
LOCKNUT, ZINC PLATED
BRACKET TO FRAME (2)
2
H9
10-24 X 1.25”,
SQUARE NECK BOLT
CARRIAGE BOLT, GRADE 2,
ZINC PLATED
COMPRESSOR MOUNTING
(4)
4
H10
10-24 HEX NUT
HEX NUT, ZINC-PLATED
COMPRESSOR MOUNTING
(4)
4
H11
M6 X 60mm, HEX
BOLT
HEX BOLT, GRADE 8.8,
ZINC PLATE
COMPRESSOR BRACKET TO
BATTERY TRAY (4)
4
H12
M6, LOCK WASHER
SPLIT LOCK WASHER, ZINC
PLATED
COMPRESSOR BRACKET TO
BATTERY TRAY (4)
4
H13
M6 X 18mm,
FENDER WASHER
FENDER WASHER, ZINC
PLATED
COMPRESSOR BRACKET TO
BATTERY TRAY (4)
4
End of Section

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7. On-Vehicle Electrical Installation
CAUTION: Follow all recommended safety precautions for working on vehicle’s electrical system; consult vehicle
owner’s manual for further instruction.
Review Suggested Wiring Diagram for Ignition Relay
Figure 2 –Suggested Ignition Relay Diagram for 230/730 Triple Train Horn

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7.1. Review suggested Wire Routing for Horn, Air Compressor, and Pressure Switch
Figure 3 –Suggested Wire Routing for Horn, Air Compressor, and Pressure Switch
7.2. Disconnect Vehicle Battery(s)

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7.3. Attach Relay to Vehicle
7.3.1. Fasten relay to vehicle body, under hood using supplied self-tapping screws. It is recommended to
install in location near factory ground bolt, or battery(s) to minimize drilling holes.
Figure 4 –Compressor Mounted, with Wiring Recommendation
Relay Provided
Inline Fuse
FRONT