Havis-Shields Kwik-Kit KK-100-05 User's Manual
Contents
1. Phillips pan head sheet metal flat washer fender washer and nut screws Approx 10 1 g KK XXX 05_INST_8 07 I Attach Ball amp Socket Style Doorstop 1 Attach Ball portion of assembly Attach to threaded hole on the door using a x 1 Hex head bolt 2 Attach the Socket and bracket portion Attach to doorframe using 8 x 34 Phillips machine screws and keps nuts Item 11 In the upper corner of each side Place trim panels as shown above Silicone all seems and joints of the 3 Compartment Pre drill through trim panel only This will allow the unit to be Doorframe are small filler with 3 16 Pre drill the vehicle hosed out panels that need to be installed w 1 8 hole and attach panels Attach using 4 x 7 carriage using 10 x 1 sheet metal screws bolts washers and serrated 1 9 KK XXX 05_INST_8 07 KK XXX 05_INST_8 07 FINAL INSTALLATION PHOTOS at 7 6 Met h b V 5 N V Q hee 20 VIDEO PT KK XXX 05_INST_8 07 21 PRISONER TRANSPORT OPTIONS All SOLD SEPERATLEY a tet F iTS P4 ECO w 7 amp 3090 7 1800 VS TCB KK PVENT IT2. or scribe is recommended to help align holes KK XXX 05_INST_8 07 13 Item 6 Place Rear Bulkhead Doorframe into vehicle Loosely bolt Rear Bulkhead Doorframe at the door hinge to Bench Wall assemblies using 4 34 carriage bolts washers and serrated nuts Item 11 to Press doorframe to align with holes in Passenger side Bench Wall assembly Item 6 to 5 Position between Driver and Loosely attach Doorframe to Center Passenger side Bench Wall divider using 10 x 3 8 flat head assemblies machine screws and nylock nuts Note It is recommended to put edge molding on the OEM door opening on the passenger side to avoid damaging the Kwik kit door Place the 3 Compartment Doorframe assembly Item 12 to 11 Align 3 Compartment Doorframe to 3 Compartment Ceiling and loosely attach 4 x 34 hex head bolts washers and serrated nuts 1 A 05 INST_8 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 34 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 posit
3. 01 KK DOME 2 PART GSM33062 GSM33308 GSM33309 GSM31048 GSM33072 GSM330015 1 USED FOR Floor wall to ceiling Vent plates dome lights Grab straps seat belts Grab straps seat belts Grab straps seat belts Bulkheads Bulkheads Bulkheads Bulkheads Ceiling vent adapter kit Ceiling USED FOR Divider to floor Divider Divider Divider Door frame to divider Door frame to divider 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
4. EM DESCRIPTION Driver side Bench Wall Passenger side Bench Wall Front Bulkhead Diamond plate Floor Divider Rear Bulkhead Doorframe Driver side Ceiling Passenger side Rear Ceiling Item 14 3 Compartment Bulkhead 3 Compartment Bench 11 3 Compartment Doorframe 12 3 Compartment Ceiling 13 3 Compartment Floor 14 2 Door Stops 15 Diamond plate floor filler panel Item 15 Item 10 Item 11 Item 9 Item 13 Item 14 0 p lt Item 6 Item 4
5. Havis Shields EQUIPMENT CORPORATION INSTALL INSTRUCTIONS KK 100 05 amp KK 120 05 KWIK KIT PRISONER TRANSPORT INSERT FORD and CHEVY VAN PRISONER TRANSPORT TOOLS REQUIRED amp 3 8 Ratcheting Wrenches 4 amp 3 8 Air Ratchets recommended 3 8 Impact Guns recommended 4 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 Table Circular Saw if necessary Utility knife Caulking gun HARDWARE 60 or 80 COMPARTMENT Some hardware not used in all application QTY DESCRIPTION 80 14 Serrated nut 60 x 34 Carriage bolt 50 10 x 1 Phillips pan head sheet metal screw 8 8 x 3 8 Phillips flat head screw 32 14 x 34 Phillips flat head machine screw 25 14 x 34 Hex head bolt 25 14 Flat washer 15 Flat washer 15 10 Lock washer 15 VY x 1 14 Socket button head bolt 4 3 8 x 2 Hex head bolt 3 8 Hex nut 3 8 Lock washer 3 8 x 2 Fender washer White Silicone tube Lock key Vent block off plate A C vent plate Dome light gt gt gt HARDWARE 40 COMPARTMENT QTY DESCRIPTION 90 14 34 Carriage bolt 90 14 Serrated nut PART USED FOR GSM30023 GSM32000 GSM33196 Floor wall to ceiling GSM33179 Vent plates dome lights GSM33078 Wal
6. Note The OEM rear Black plastic trim will remain Photos show without Trim Note Photos above show a Chevrolet Van Photos are intended to show rubber floor mat option only PASSENGER WINDOW VAN PREPARATIONS 1 Remove all rear bench seats from the vehicle 2 Modify remove interior parts as needed 3 Remove floor mat carpet and replace with 1 2 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 Kwik kits are designed for cargo vans with no rear OEM trim however they can be installed into passenger window vans Some rear trim removal or modification is required Do not remove all rear trim and headliner as this will aid in sound deadening amp insulation UNPACKING AND INSTALLATION Refer to exploded view drawing on page 16 to identify parts A KK XXX 05_INST_8 07 1 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 2 and bra
7. ckets 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 i 14 tale 14 4 5 KK XXX 05_INST_8 07 Remove all black hardware from assembled unit This will give you the subassemblies as they are shown on the following pages lt gt WK KK KY 6 KK XXX 05_INST_8 07 The following photos the main subassemblies as they are shipped from the factory Remove drawing on final page and reference the item s as you install this kit Item 2 y Item 3 Driver Side Bench Wall Passenger Side Rear Bench Wall Front Bulkhead minus driver side Front bulkhead wing section 3 Compartment Bulkhead Wing section Wing section Item 4 amp Center Divider Driver side ceiling Item 9 Item 10 Passenger side rear ceiling 3 compartment bulkhead 3 Compartment bench w optional storage door 7 KK XXX 05_INST_8 07 4 3 Compartment ceiling Rear bulkhead door assembly 3 Compartment Bulkhead door assembly KWIK KIT LAYOUT Diamond plate floor and ceiling sections are not shown for detail purposes KK XXX 05_INST_8 07 VERY IMPORTANT Be sure that all Auxiliary lighting v
8. etc This will also help deaden the echo in the vehicle e OPTION 2 3 8 to plywood can also be used as an alternative solution Cover the entire cargo floor of the van 1 1 2 48 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 05_INST_8 07 Rear OEM Trim modifications 1997 2007 Chevrolet G Series Van Installation of Kwik Kit is 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 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 15 the starting position so parts fit into the correct locations Note With OEM rear AC Heat The kit will be shifted to passenger side Van does NOT require rear trim modification 3 KK XXX 05_INST_8 07 Ford Van Driver Side rear Ford Van Passenger Side rear 8 to 8 4 Note Exact position may not be square to Driver side if van has OEM rear Air conditioning 8inches to rear body flange
9. ideo systems Kwik kit options and wiring are complete Access is severely limited after kit is installed Notch trim for wiring Pillar 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 9 KK XXX 05_INST_8 07 Place Driver side Bench Wall Place Passenger side assembly into van so bench rests 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 Place Front Bulkhead into Attach Front Bulkhead to View of Emergency Exit Hatch vehicle Driver side Bench Wall s
10. ion Lower Driver Side rear Lower Passenger Side rear Item 1 Rear driver side doorframe wing Position of driver side Rear Measurement 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 14 of space between the A C blower motor and wing 1 5 05 INST_8 07 Top Driver Side rear Top Passenger Side rear Item 6 Item 6 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 1 6 05 INST_8 07 Be careful when pre drilling not to hit hoses wires etc Item 8 to 2 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 14 x 1 42 hex on the Passenger side Ceiling section head lag bolts 7 Item 5 through 8 into 7 gt Pre drill through Cei
11. l Bench extension GSM33001 divider 3 ceiling GSM31005 divider ceiling GSM3 1009 Grab straps seat belts GSM31030 Grab straps seat belts GSM33310 Grab straps seat belts GSM33032 1 Bulkheads GSM30008 Bulkheads GSM31028 Bulkheads GSM3 1022 Bulkheads PRM97343 Seams amp Gaps PRM97660 1 Doors KKM0403 004 Ceiling vent adapter kit KKM0403 001 Ceiling vent adapter kit KK DOME 2 Ceiling PART USED FOR GSM32000 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 10 Flat washer 15 Lock washer VY x 1 14 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 HARDWARE DIVIDER QTY DESCRIPTION 28 x Hex head lag bolt 14 14 x 5 8 Stainless socket button head bolt 7 14 x 34 Stainless socket button head bolt 14 14 Stainless flat washer 10 10 x 2 Phillips flat head machine screw 10 10 Thin nylock nut Pe Always Read all instructions before installing any Havis Shields Equipment Corp products Check for obstructions Wire brake lines fuel tank etc before drilling any holes Use hardware provided with install kit PART GSM33196 GSM33179 GSM31009 GSM31030 GSM33310 GSM33032 1 GSM30008 GSM31028 GSM31022 KKM0403 0
12. ling sections using Attach remainder of Diamond plate floor Pre drill Divider as a template with 3 16 drill diamond 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 Begin to tighten ALL loose hardware the remainder of the unit being sure to align edges and bends of materials being tightened This will square the unit to itself Attach to wood floor or rubber floor mat using 10 x 1 Phillips pan head sheet metal screws 17 KK XXX 05_INST_8 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 I N 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 e Item 13 Item 11 I Attach the doorframe to the Secure the Front Bulkhead Drill 2 Place 3 Compartment Floor vehicle using 10 x 1 Phillips one per side 3 8 holes through the Pre drill diamond plate floor pan head sheet metal screws frame 2 plywood and floor of vehicle only and attach using 10 x 1 Attach using 3 8 x 2 hex head bolt
13. upport bracket assembled assembly 1 0 05 INST_8 07 Be careful that exposed wires are not touching metal and optional KK Place 2 Diamond Plate Floors x VAK hoses 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 positioning shape the airflow will still be good Avoid completely crushing hoses the floor to avoid scratching the bench pesa aai 4 0 F g m A i k 8 D a 7 4 a The floor s will square the benches Place Center Divider into Approximate center and bulkheads to the kit vehicle Item 5 to 3 fi Item 7 Loosely bolt Center Divider to Current view of installation Carefully place Driver side Front Bulkhead Ceiling section into vehicle 1 1 05 INST_8 07 Place Passenger side Ceiling section Route dome light wires HVAC Current view of installation into vehicle hoses video cables etc to their Do not attach any hardware at this time respective locations Item 7 amp 8 N Item 12 _ Slide the ceiling sections out of way in order to access A C hoses wires etc Position 3 Compartment Note These components will be hard to access once ceiling is mounted Ceiling into vehicle Remove all slack from hoses to maximize airflo
14. w Item 9 Remove screws holding the center Remove 3 Compartment Position 3 Compartment divider together where 3 Bulkhead Emergency Exit Bulkhead as shown above Compartment Bulkhead will be Hatch to ease installation mounted 1 7 05 INST_8 07 Bolt 3 Compartment Bench to 3 Compartment Divider using 14 x 34 carriage bolts and serrated nuts Nuts should be on the inside of the bench Place 3 compartment bench Photo shows optional storage door Note Be careful not to scratch bulkheads VERY IMPORTANT Items 9 8 amp 12 all bolt together Item 9 to 5 Re install screws removed in step above and loosely attach aligning all three materials Note An awe or scribe is Position 3 compartment ceiling and loosely attach a few 14 x 34 hex head bolts and washers where 3 compartment divider and ceiling meet with rear passenger side ceiling This is the most difficult section to install due to aligning all 3 materials Be sure to do this step prior to recommended to help align holes d attaching any part of ceilings or 3 compartment divider Item 9 to 2 f Z 4 Item 9 to 2 Loosely bolt Passenger side Bench Wall assembly to 3 Bolt 3 Compartment Divider to Compartment Bulkhead using 14 x 34 Carriage bolts and Passenger side Wall using 14 x 34 serrated nuts carriage bolts washers and nuts Note An awe
Download Pdf Manuals
Related Search