Klenn Air Horns GMTRK4 User manual

GMTRK4
INSTALLATION MANUAL
© Kleinn Air Horns 2020, All rights reserved.
PO Box 91278 Tucson, AZ 85752
Phone: [phone]
Web: www.Kleinn.com
REV: BETA (4/4/2020)

GMTRK4
Installation and Operation Manual
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GMTRK4
Installation and Operation Manual
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Table of Contents
1. LIST OF FIGURES................................................................................................................................... 5
2. How to Use this Manual ...................................................................................................................... 6
2.1. Interactive Manual using Adobe Reader...................................................................................... 6
2.2. Your Kit SKU Number and this Manual ........................................................................................ 6
2.3. Illustration/Photo Details and Orientation .................................................................................. 6
3. Safety First ........................................................................................................................................... 7
4. Application Chart................................................................................................................................. 8
4.1. Bolt-On Vehicle List ...................................................................................................................... 8
4.2. **Excluded Vehicles..................................................................................................................... 8
4.3. Aftermarket Product Compatibility.............................................................................................. 8
5. Installation Overview........................................................................................................................... 9
5.1. Kit Layout and System Location(s) ............................................................................................... 9
5.2. Install Process Outline................................................................................................................ 11
5.3. Approximate Installation Time................................................................................................... 11
6. List of Tools and Supplies .................................................................................................................. 12
6.1. Standard Tool List (Required)..................................................................................................... 12
6.2. Special Tool List (Recommended).............................................................................................. 12
6.3. Shop Consumables List (Recommended)................................................................................... 12
7. Parts List............................................................................................................................................. 13
7.1. Before Starting, Review Parts List.............................................................................................. 13
7.2. Pre-Packaged 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 Soft Parts........................................................................................... 17
7.7. Add-On Accessories.................................................................................................................... 19
8. Bench Assembly................................................................................................................................. 20
8.1. Assemble Air Fittings to Air Tank ............................................................................................... 20
8.2. Assemble Air Filter to Air Compressor....................................................................................... 21
8.3. Disassemble Trumpets from Air Horn Drivers ........................................................................... 21
8.4. Assemble Air Horn Driver to Horn Bracket (GMTRK-4-301) ...................................................... 22
8.5. Insert Square Neck Bolts onto Brackets (GMTRK-4-102, 201)................................................... 24
9. On-Vehicle Mechanical Assembly ..................................................................................................... 25
9.1. Trim Driver’s Side OE Leaf Spring Shackle Bolt .......................................................................... 25
9.2. Install Air Tank & Compressor Bracket (GMTRK-4-201) & Bolt Plate (-102).............................. 26
9.3. Install Air Tank............................................................................................................................ 28
9.4. Install Air Compressor................................................................................................................ 30
9.5. Connect Air Compressor Leader Hose to Air Tank..................................................................... 31
9.6. Remove OE Engine Shield & OE Clip-On Nut ............................................................................. 32
9.7. Install Air Horn Driver Sub-Assembly & Connect Air Tubing...................................................... 33
9.8. Connect Air Horn Tubing to Air Tank ......................................................................................... 35
9.9. Final Trumpet Installation .......................................................................................................... 36

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Installation and Operation Manual
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10. On-Vehicle Electrical Installation....................................................................................................... 37
10.1.Relay and Fuse Diagram for Air Horn System ............................................................................ 37
10.2.Suggested Wire Routing for Air Horn System ............................................................................ 38
10.3.Disconnect Vehicle Battery(s) .................................................................................................... 38
10.4.Connect Wiring 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 & Testing ......................................................................................................................... 40
11.1.Reconnect Vehicle Battery(s)..................................................................................................... 40
11.2.Test Air Compressor................................................................................................................... 40
11.3.Test Train Horns ......................................................................................................................... 40
11.4.Test Quick Connect Coupler....................................................................................................... 40
12. General Operation............................................................................................................................. 41
12.1.Compressor Operation............................................................................................................... 41
12.2.Horn Operation .......................................................................................................................... 41
13. Routine Maintenance........................................................................................................................ 41
14. Warranty Information ....................................................................................................................... 42
End of Table of Contents

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Installation and Operation Manual
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1. LIST OF FIGURES
Figure 1 –Above Vehicle View Showing Kit Layout (2019 Silverado 1500 Crew Cab Short Bed Shown) ....................................9
Figure 2 –Under Vehicle View of Air Horn Installed –Behind Front Bumper (2020 Silverado Shown) ....................................10
Figure 3 –Under Vehicle view of Air Tank Installed –Behind Driver Bed Side (2020 Silverado Shown)...................................10
Figure 4 –Under Vehicle view of Air Compressor Installed –Behind Driver Wheel (2020 Silverado Shown) ..........................10
Figure 5 –Air Fittings installed on Air Tank (Side Exploded view, as shown resting on bench) ................................................20
Figure 6 –Air Fittings Orientation (Top, Back & Inboard view, as shown if installed in Vehicle) ..............................................20
Figure 7 –Air Compressor remote Air Filter and Tubing (shown without Air Compressor)......................................................21
Figure 8 –Removing Trumpets from Air Horn Driver, Exploded View ......................................................................................21
Figure 9 –Air Horn Fitting Orientation (Air Horn Driver shown assembled to Bracket as if sitting on bench) .........................22
Figure 10 –Air Horn Driver Assembled to Bracket (Exploded View) .........................................................................................23
Figure 11 –GMTRK-4-102 Plate with Bolts pressed in place (Exploded View)..........................................................................24
Figure 12 –GMTRK-4-201 Tank Bracket with Bolts pressed in place (Exploded View) .............................................................24
Figure 13 –Underbody view of Driver’s side Leaf Spring Shackle Bolt (2020 Silverado shown) ...............................................25
Figure 14 –Underbody view of Driver’s side Leaf Spring Shackle Bolt trimmed (2020 Silverado shown) ................................25
Figure 15 –Underbody view of Driver’s side mounting holes (2020 Silverado shown) ............................................................26
Figure 16 –Installing GMTRK-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 19 –Installing Air Tank onto Air Tank Bracket (2020 Silverado Shown) .........................................................................28
Figure 20 –Air Tank Assembly onto Bracket (Exploded View) ..................................................................................................29
Figure 21 –Air Compressor Assembly onto Bracket (Exploded View).......................................................................................30
Figure 22 –Air Compressor Leader Hose Route & Zip Ties (Shown as if installed in vehicle) ...................................................31
Figure 23 –Engine Shield Bolts removal (2020 Silverado 5.3L Shown) .....................................................................................32
Figure 24 –Engine Shield Clip-On Nut removal; Hardware H6 & H9 shown installed (2020 Silverado Shown)........................32
Figure 25 –Air Horn Sub-Assembly installed over Frame with H12 Clip-On Nut (2020 Silverado Shown) ...............................33
Figure 26 –Air Horn Sub-Assembly installed with Engine Shield in place (2020 Silverado Shown) ..........................................33
Figure 27 –Installing Air Horn Sub-Assembly over Frame (Exploded View)..............................................................................34
Figure 28 –Connecting Air Tubing to Air Horn Driver (Shown as if installed in vehicle) ...........................................................34
Figure 29 –102 Air Horn Tubing Routed through Front Suspension Tower (Shown as if installed on Vehicle)........................35
Figure 30 –Air Tank Air Tubing Route with Rubber Grommets (Shown as if installed in vehicle) ............................................35
Figure 31 –Re-attaching Trumpets (Exploded View shown as if installed in vehicle)...............................................................36
Figure 32 –Suggested Ignition Relay Diagram for Air Horn System (Single 220 Horn Shown) .................................................37
Figure 33 –Suggested Wire Routing for Horn, Air Compressor, and Pressure Switch (GMTRK4 Shown) .................................38
Figure 34 –Relay and Fuse location example under hood (2020 Silverado 5.3L Shown)..........................................................38
Figure 35 –Horn Button Installed in Dash and OE Upfitter Switches (Shown in example vehicles) .........................................39
End of Figures

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Installation and Operation Manual
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2. How to Use this Manual
2.1. 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 ®
On PC, or Mac
•visit https://get.adobe.com/reader/otherversions/
On Android, iPhone/iPad, and Windows devices,
•visit https://acrobat.adobe.com/us/en/acrobat/mobile-app.html
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 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.
2.3. 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 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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Installation and Operation Manual
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3. 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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Installation and Operation Manual
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4. Application Chart
4.1. Bolt-On Vehicle List
GMTRK4 is a 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
2019-2020
SILVERADO 1500
ALL
ALL
ALL
ALL**
2019-2020
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.
It is also recommended to shorten one OE Bolt by cutting/grinding its non threaded end to provide Air Tank
clearance –see Mechanical 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:
•Most aftermarket suspension systems that directly-bolt on (i.e., utilize OE mounting points)
•Aftermarket power steps and rocker steps/running boards
•Aftermarket exhaust systems
4.3.2. This kit has NOT been designed to be compatible with any of the following products:
•Aftermarket front bumpers that do not have same empty space behind Driver’s side of OE bumper
•Aftermarket fender flares that require cutting rear bed sides and OE rock guarding
NOTE: Review this manual in full before unpacking items and verify correct space and mounting locations
exist with your aftermarket product(s). To install this kit alongside your other aftermarket product(s),
modification to included parts, your vehicle, or aftermarket product(s) may be required.
End of Section

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Installation and Operation Manual
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5. Installation Overview
5.1. Kit Layout and System Location(s)
GMTRK4 consists of following components, located on vehicle, as follows:
ITEM
DESCRIPTION
VEHICLE LOCATION
MOUNTING
METHOD
APPROX.
INSTALL TIME
1
6260RC 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)
Bracket bolts to Bed &
Wheel Rock Guard
1-2 Hours
3
102 Series Air Horn
with Air Solenoid
Front Bumper, Driver Side
(behind Bumper, outside Frame)
Bracket bolts to Frame
above Engine Shield
1-2 Hours
Figure 1 –Above Vehicle View Showing Kit Layout (2019 Silverado 1500 Crew Cab Short Bed Shown)
3
2
FRONT

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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 –Under Vehicle view of Air Compressor Installed –Behind Driver Wheel (2020 Silverado Shown)
FRONT