Havis-Shields Kwik-Kit KK-100-03 User's Manual
Contents
1. m Poke tl AP AAR i KAUM a tele k vu stue YN KK XXX 03 INST 10 07 the ive you ages is will Remove all black hardware from assembled unit Th subassemblies as they are shown on the followin K R 4747990 9 W W KK x rat F PL U p pur KK XXX 03 INST 10 07 VERY IMPORTANT Be sure that all Auxiliary lighting video systems Kwik kit options and wiring are complete Access is severely limited after kit is installed Notch trim for wiring If optional rear load light s Run all wiring for dome lights power For neatness of wiring route all KK RLL was ordered install at vents video system HVAC etc at cables down driver side B pillar this time this time Tie to existing OEM harness If going under hood for power to See KK RLL install instructions console drill hole at location above Be sure to tape harnesses to roof in At this time go to the KK x VAK If optional Power Vent s approximate locations that install instructions This must be KK PVENT was ordered see accessories are being installed in installed prior to Kwik Kit those instructions at this time for Kwik kit This will vary between necessary prep work that must be the different model kits done prior to installing Kwik Kit 7 KK XXX 03 INST 10 07 Item 1 ye kL pa p Ite Place Driver side Bench Wall Place Passenger side assembly into van so bench res2. 2 3 8 to 2 plywood can also be used as an alternative solution Cover the entire cargo floor of the van 1 2 48 x 96 sheets of plywood are needed Havis Shields Equipment Corp does not supply plywood floor kit Draw a line on the rubber wood floor from rear doorframe as shown on the following page This will be the starting point of the kit KK XXX 03 INST 10 07 Rear OEM Trim modifications 1997 2008 Chevrolet G Series Van Installation of Kwik Kit 1s very similar in Ford and Chevy Vans All kits start with a measurement at the rear floor The rear plastic floor trim on Chevy vans must be cut straight across as shown in photo Measure seven inches 7 1 4 from rear center of trim and cut straight line full width Jig saw works well for this step After plastic trim is cut and back in it s original location you must measure 7 inches forward on both sides from newly cut trim to place rear Kwik Kit bulkhead This is the starting position so parts fit into the correct locations Note With OEM rear AC Heat The kit will be shifted to passenger side Ford Van does NOT require rear trim modification 3 KK XXX 03 INST 10 07 Ford Driver Side rear Ford Passenger Side rear 139 3 ar s a 8 inches 3 PASSENGER WINDOW VAN PREPARATIONS Kwik kits are designed for cargo vans with no rear OEM trim however they can be installed into passenger window vans Some rear
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4. Bulkheads 2 White Silicone tube PRM97343 Seams amp Gaps 4 Lock key PRM97660 1 Doors 4 Vent block off plate KKM0403 004 Ceiling vent adapter kit 2 A C vent plate KKMO0403 001 Ceiling vent adapter kit 2 Dome light KK DOME 2 Ceiling HARDWARE 40 COMPARTMENT OTY DESCRIPTION PART USED FOR 90 1 4 x Ya Carriage bolt GSM32000 90 1 4 Serrated nut GSM30023 40 COMPARTMENT cont QTY DESCRIPTION 40 10 x 1 Phillips pan head sheet metal screw 25 8 x 3 8 Phillips flat head screw 1 2 Flat washer 1 2 Lock washer 1 x 1 1 2 Socket button head bolt 3 8 x 2 Hex head bolt 3 8 Hex nut 3 8 Lock washer 3 8 x 2 Fender washer A C Vent plate Dome light Un 2 CA QA nm On AG A HARDWARE DIVIDER QTY DESCRIPTION 28 Ya x 1 1 2 Hex head lag bolt 14 la x 5 8 Stainless socket button head bolt J 4 x 3 2 Stainless socket button head bolt 14 4 Stainless flat washer 10 10 x 2 Phillips flat head machine screw 10 10 Thin nylock nut PART GSM33196 GSM33179 GSM3 1009 GSM3 1030 GSM33310 GSM33032 1 GSM30008 GSM31028 GSM3 1022 KKM0403 001 KK DOME 2 PART GSM33062 GSM33308 GSM33309 GSM3 1048 GSM33072 GSM330015 1 Always Use hardware provided with install kit v v v v USED FOR Floor wall to ceiling Vent plates dome lights Grab straps seat belts Grab straps seat belts Grab straps seat belts Bulkheads Bulkheads
5. Rear Bulkhead Position between Driver and Loosely attach Doorframe to Center Doorframe into vehicle Passenger side Bench W all divider using 10 x 3 8 flat head assemblies machine screws and nylock nuts Item 6 to 2 Loosely bolt Rear Bulkhead W ote It po dk ign Place the 3 Compartment Doorframe at the door hinge to eage molding on the oor Bench Wall assemblies using Y4 opening on the passenger side to x 3 2 carriage bolts washers and avoid damaging the Kwik kit serrated nuts door Doorframe assembly Item 12 to 11 Align 3 Compartment Doorframe to 3 Compartment Ceiling and loosely attach 1 4 x 3 4 hex head bolts washers and serrated nuts Press doorframe to align with holes in Passenger side Bench Wall assembly 12 KK XXX 03 INST 10 07 Item 7 8 12 to 3 amp 6 Continue around the entire kit bolting An awe or scribe will help Tighten screws holding Rear all Ceiling pieces to Bulkheads and align the holes Doorframe to Center Divider Doorframes using 4 x carriage bolts washers and serrated nuts Cut door gasket with utility knife Cut gasket to the length Position the entire unit according to the of door acceptor frame Attach as shown above measurements on the following page Note Maneuver the kit into position Lower Driver Side rear Lower Passenger Side rear Item 1 Rear driver side i doorframe wing 8 inches Position of driver side Rear M
6. trim removal or modification ts required Do not remove all rear trim and headliner as this will aid in sound deadening amp insulation Note Kwik Kits are recommended for Cargo Vans The installer must determine modifications to the interior of a window van 1 Remove all rear bench seats from the vehicle 2 Modify remove interior parts as needed 3 Remove floor mat carpet and replace with 4 plywood or sound deadening material Recommended 4 If installing KK F VAK OEM air conditioning adapter cut or remove all plastic trim around the rear OEM system UNPACKING AND INSTALLATION Refer to exploded view drawing on page 22 to identify parts 4 KK XXX 03 INST 10 07 l Remove clear shrink wrap covering the prisoner transport assembly 2 This is the rear 40 60 or 80 section of the kit 3 Remove all black hardware wood panels and brackets holding wood panels 4 Remove bolts holding the kit to the wood pallet 5 With all hardware removed the remaining sections should match the sub assemblies on the following pages Remove clear shrink wrap covering from prisoner transport assembly This is the 3 compartment 40 section Remove all black hardware wood fillers and brackets holding assemblies Remove bolts holding the kit to the wood pallet With all hardware removed the remaining sections should match the sub assemblies on the following pages E E Fa Fylit p ur HE de MW F
7. Bulkheads Bulkheads Ceiling vent adapter kit Ceiling USED FOR Divider to floor Divider Divider Divider Door frame to divider Door frame to divider Read all instructions before installing any Havis Shields Equipment Corp products Check for obstructions Wire brake lines fuel tank etc before drilling any holes For product support visit the Install Instructions Section of our website at http havis com Installation Installation html email technicalsupport havis com or call 1 800 524 9900 gt If this is your first time installing a Havis Shields Equipment Corp Prisoner Transport please contact the factory for tips and suggestions that will ease the installation VEHICLE PREPERATION 1 STEPS HVAC VAK OPTIONS ETC e Refer to the specific install instructions Installing the steps prior to installing the Kwik Kit will ease installation and must be done on Chevy side step e Installing options may be necessary prior to installing the kit 2 SOUND DEADENING amp FLOORING e OPTION 1 KK RFM A self adhesive rubber sound deadening floor mat is sold separately and will help deaden road noise e Install optional rubber flooring onto van floor Rubber floor mat should go under OEM floor mat in drivers compartment to cover sheet metal floor e Excess material can be placed onto walls of the van around the wheel wells inside door panels etc This will also help deaden the echo In the vehicle e OPTION
8. Havis Shields EQUIPMENT CORPORATION INSTALL INSTRUCTIONS KK 100 03 amp KK 120 03 KWIK KIT PRISONER TRANSPORT INSERT FORD and CHEVY VAN PRISONER TRANSPORT TOOLS REQUIRED 4 amp 3 8 Ratcheting Wrenches Ya amp 3 8 Air Ratchets recommended 3 8 Impact Guns recommended Ya amp 3 8 Standard Socket Sets Powered Drill Powered Screwdriver recommended Drill Bit Set Tape Measure Screwdriver Set Awe or Scribe Pry bar Wire Crimping tool Wire Stripping tool Wire Cutter Circular Saw for plywood Utility knife Caulking gun HARDWARE 60 or 80 COMPARTMENT Some hardware not used in all application QTY DESCRIPTION PART USED FOR 80 1 4 Serrated nut GSM30023 60 4 x 3 2 Carriage bolt GSM32000 50 10 x 1 Phillips pan head sheet metal screw GSM33196 Floor wall to ceiling 8 8 x 3 8 Phillips flat head screw GSM33179 Vent plates dome lights 32 Ya x Phillips flat head machine screw GSM33078 Wall Bench extension 25 4 x Ya Hex head bolt GSM33001 3 divider 3 ceiling 25 4 Flat washer GSM31005 3 divider 3 ceiling 15 2 Flat washer GSM31009 Grab straps seat belts 15 1 Lock washer GSM3 1030 Grab straps seat belts 15 1 x 1 1 4 Socket button head bolt GSM33310 Grab straps seat belts 4 3 8 x 2 Hex head bolt GSM33032 1 Bulkheads 4 3 8 Hex nut GSM30008 Bulkheads 4 3 8 Lock washer GSM31028 Bulkheads 4 3 8 x 2 Fender washer GSM31022
9. amond floor only w 3 16 hole and 1 8 hole through bit and attach using 1 4 x 1 1 2 hex head floor of vehicle lag bolts Through Item 4 1 amp van floor Attach to wood floor or rubber floor mat using 10 x 1 Phillips pan head sheet metal screws Begin to tighten ALL loose hardware on the remainder of the unit being sure to align edges and bends of materials being tightened This will square the unit to itself 15 KK XXX 03 INST 10 07 On the Rear doorframe remove the sheet metal screws installed earlier Drill 3 8 holes through the doorframe floor and vehicle Attach using 3 8 x 2 hex head bolts washers fender washers lock washers and hex nuts Item 6 to van floor Item 11 to van floor ha lt W On 3 Compartment Doorframe repeat the same steps done on Rear Doorframe Only one bolt is used and must be located just to the left of the doors hinge as shown above 3 8 x 2 hex head bolt flat washer I Attach the doorframe to the vehicle aes me oe Pal OT H al on x U per per side 3 8 holes through the frame 2 using 10 x 1 Phillips pan head sheet plywood and floor of vehicle Attach using ESN 3 8 x 2 hex head bolt flat washer fender washer and nut 16 KK XXX 03 INST 10 07 Y i Attach Ball amp Socket Style Doorstop 1 Attach Pin portion of assembly Attach to threaded hole on the door
10. easurement from driver side Measurement from passenger side Doorframe when installing with Rear Doorframe to vehicle Rear Doorframe to vehicle factory rear air There should be at doorframe shown above doorframe shown above least 4 of space between the A C blower motor and wing 13 KK XXX 03 INST 10 07 Top Driver Side rear i Top Passenger Side rear Approximately 3 inches Item 7 to 1 With unit positioned according to measurements on previous page pre Position Driver side Ceiling section to drill and attach a 10 x 1 sheet metal screw to hold the rear Bulkhead in mate with Bench Wall assembly Pre place while assembling the remainder of the unit drill 5 32 holes into Ceiling using Bench Wall assembly holes as a guide 14 KK XXX 03 INST 10 07 Be careful when pre drilling not to htt hoses wires etc Note Ceiling is behind wall V I w ase Pre drill ceiling with 5 32 drill bit and attach 10 x Be Sure Floor Is Square To Benches amp Bulkheads 1 Phillips pan head sheet metal screws to hold Attach Divider to vehicle Pre drill through floor s Ceiling to Bench Wall assembly Repeat these steps using 3 16 drill bit and attach using 4 x 1 1 2 hex on the Passenger side Ceiling section head lag bolts Item 5 through 8 into 7 P d Pre drill through Ceiling sections using Attach remainder of Diamond plate floor Pre drill Divider as a template with 3 16 drill di
11. respective locations Item 7 amp 8 Zt ft While pt as FL Fj p Slide the ceiling sections out of the way in order to access A C hoses wires etc Remove Bulkhead Emergency Note These components will be hard to access once ceiling is mounted Exit Hatches to ease installation Remove all slack from hoses to maximize airflow Install forward compartment driver sidewall bench assembly Item 10 Install forward compartment ceiling assembly Item 12 Place rear facing bench against front bulkhead Item 16 Position Middle Bulkhead to separate front and rear compartments 10 KK XXX 03 INST 10 07 Rear Facing bench Use under seat flange holes to mark Drill floor flange and side seat and Drill through front bulkhead flange with a 5 32 drill bit with 4 bit Use 1 4 x bolts and serrated to attach seat to bulkhead Attach floor flange and side seat Attach seat cover plate with 10 x flange with 10 x pan head sheet 2 flat head sheet metal screws metal screws Item 9 to 2 l Wa Loosely bolt Passenger side rear ceilings Bench Wall Bolt side door and door frame assembly to Middle Bulkhead using 4 x 3 2 Carriage bolts and serrated nuts Note An awe or scribe is recommended to help align holes assembly using 4 x 3 4 carriage bolts washers and nuts 11 KK XXX 03 INST 10 07 N K E 1 i l i 4 b L br TER Place
12. ts Bench Wall assembly into van so on wheel well bench rests on wheel well Remove steel support bracket for Remove Emergency Exit Hatch Emergency Exit Hatch pin Re install from Front Bulkhead to ease when attaching Front Bulkhead to installation Bench Wall assemblies Item 3 gt gt gt i Place Front Bulkhead into Attach Front Bulkhead to View of Emergency Exit Hatch vehicle Driver side Bench Wall support bracket assembled assembly Q KK XXX 03 INST 10 07 Be careful that exposed wires are not touching metal and optional KK Place 2 Diamond Plate Floors x VAK hoses are not completely crushed between Bench Wall assemblies and Front bulkhead Place cardboard Note Vent hose will be tight in spots If hose are crushed to an oval along side of bench while positionin Shape the airflow will still be good Avoid completely crushing hoses the floor to avoid scratching the bench The floor s will square the benches Place Center Divider into vehicle NOTE Some installers and bulkheads to the kit prefer to install ceiling prior to divider Item 5 to 3 Loosely bolt Center Divider to Current view of installation Carefully place Driver side Front Bulkhead Ceiling section into vehicle 9 KK XXX 03 INST 10 07 Place Passenger side Ceiling section into Route dome light wires HVAC Current view of installation vehicle hoses video cables etc to their Do not attach any hardware at this time
13. using a 1 2 x 1 Hex head bolt 2 Attach the Socket and bracket portion Attach to doorframe using 8 x Phillips machine screws and keps nuts e i In the upper corner of each side of the 3 Compartment Doorframe are small filler panels that need to be installed Attach using 4 x 3 4 carriage bolts washers and serrated Item 15 Place trim panels as shown above Pre drill through trim panel only with 3 16 Pre drill the vehicle w 1 8 hole and attach panels using 10 x 1 sheet metal screws Silicone all seems and joints This will allow the unit to be hosed out 17 KK XXX 03 INST 10 07 FINAL INSTALLATION PHOTOS _ T eS m z FE s s g a Forward Compartment for models KK 100 03 KK 100 04 KK 120 03 and KK 120 04 Optional Storage Compartment Sold Separately 18 KK XXX 03 INST 10 07 PRISONER TRANSPORT OPTIONS All SOLD SEPERATLEY Setelelts dd pel w SANS ETE kg a H Piit i ta eter REC L ai VS 1800 ECO w C TCB 7 amp C C 3090 7 KK XXX 03 INST 10 07 19 SI Wa pued JOT IJ 10013 oye d puowleiq GI cu paint 9 Way sdoys 100 7 pI T1OOJ Juounieduuoo W014 I suro 1uounieduioo 1UOL TI awesjlooq 1u unieduroo Wo II ET WJI youog T juounieduroo 1UOLJ OI peouyyng IojeredaS 6 SUIA IY APIS losuasseg 6 WJ SUIN IY PIS IDA Nq hI Woy FI Wwy swe1100G peayy ng wy TODTATCT
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