Havis-Shields KK-100-06, KK-120-06 User Manual

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INSTALL INSTRUCTIONS KK-100-06 & KK-120-06

KWIK-KIT PRISONER TRANSPORT INSERT

FORD and CHEVY VAN PRISONER TRANSPORT

TOOLS REQUIRED:

 

¼” & 3/8” Ratcheting Wrenches

Awe or Scribe

¼” & 3/8”Air Ratchets (recommended)

Pry-bar

3/8” Impact Guns (recommended)

Wire Crimping tool

¼” & 3/8” Standard Socket Sets

Wire Stripping tool

Powered Drill

Wire Cutter

Powered Screwdriver (recommended)

Table/Circular Saw (if necessary)

Drill Bit Set

Utility knife

Tape Measure

Caulking gun

Screwdriver Set

 

HARDWARE - 60” or 80” COMPARTMENT: Some hardware not used in all application:

QTY

DESCRIPTION

PART #

USED FOR:

80

¼” Serrated nut

GSM30023

 

60

¼” x ¾” 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

¼” x ¾” Phillips flat head machine screw

GSM33078

Wall/Bench extension

25

¼” x ¾” Hex head bolt

GSM33001

3rd divider, 3rd ceiling

25

¼” Flat washer

GSM31005

3rd divider, 3rd ceiling

15

½” Flat washer

GSM31009

Grab straps/seat belts

15

½” Lock washer

GSM31030

Grab straps/seat belts

15

½” x 1 ¼” 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

Bulkheads

2

White Silicone tube

PRM97343

Seams & Gaps

4

Lock key

PRM97660-1

Doors

4

Vent block off plate

KKM0403-004

Ceiling (vent adapter kit)

2

A/C vent plate

KKM0403-001

Ceiling (vent adapter kit)

2

Dome light

KK-DOME-2

Ceiling

HARDWARE - 40” COMPARTMENT:

 

 

QTY

DESCRIPTION

PART #

USED FOR:

90

¼” x ¾” Carriage bolt

GSM32000

 

90

¼” Serrated nut

GSM30023

 

40” COMPARTMENT (cont):

 

 

QTY

DESCRIPTION

PART #

USED FOR:

40

#10 x 1” Phillips pan head sheet metal screw

GSM33196

Floor, wall to ceiling

25

#8 x 3/8” Phillips flat head screw

GSM33179

Vent plates/dome lights

5

½” Flat washer

GSM31009

Grab straps/seat belts

5

½” Lock washer

GSM31030

Grab straps/seat belts

5

½” x 1 ¼” Socket button head bolt

GSM33310

Grab straps/seat belts

5

3/8” x 2” Hex head bolt

GSM33032-1

Bulkheads

5

3/8” Hex nut

GSM30008

Bulkheads

5

3/8” Lock washer

GSM31028

Bulkheads

5

3/8” x 2” Fender washer

GSM31022

Bulkheads

2

A/C Vent plate

KKM0403-001

Ceiling (vent adapter kit)

1

Dome light

KK-DOME-2

Ceiling

HARDWARE – DIVIDER:

 

 

QTY

DESCRIPTION

PART #

USED FOR:

28

¼” x 1 ½” Hex head lag bolt

GSM33062

Divider to floor

14

¼” x 5/8” Stainless socket button head bolt

GSM33308

Divider

7

¼” x ¾” Stainless socket button head bolt

GSM33309

Divider

14

¼” Stainless flat washer

GSM31048

Divider

10

#10 x ½” Phillips flat head machine screw

GSM33072

Door frame to divider

10

#10 Thin nylock nut

GSM330015-1

Door frame to divider

Always!

¾Read all instructions before installing any Havis-Shields Equipment Corp products.

¾Check for obstructions (Wire, brake lines, fuel tank, etc.) before drilling any holes!

¾Use hardware provided with install kit

¾For 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.

¾If 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:

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.

Installing options may be necessary prior to installing the kit.

2.SOUND DEADENING & FLOORING:

OPTION #1: KK-RFM A self-adhesive rubber sound deadening floor mat is sold separately and will help deaden road noise.

Install optional rubber flooring onto van floor. Rubber floor mat should go under OEM floor mat in drivers compartment to cover sheet metal floor.

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.

OPTION #2: 3/8” to ½” plywood can also be used as an alternative solution. Cover the entire cargo floor of the van. (1 ½) – 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.

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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 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-06_INST_8-07

Ford Driver-Side rear

Ford Passenger-Side rear

8”inches

 

8” inches

 

 

 

Note: Photos above show a Chevrolet Van. Photos are intended to show rubber floor mat option only.

***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 & insulation

3.PASSENGER WINDOW VAN PREPARATIONS:

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 ½” 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 ***

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KK-XXX-06_INST_8-07

Havis-Shields KK-100-06, KK-120-06 User Manual

1.Remove clear shrinkwrap 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

1.Remove clear shrink-wrap covering from prisoner transport assembly.

2.This is the 3rd compartment, 40 section

3.Remove all black hardware, wood fillers, and brackets holding assemblies.

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

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Remove all black hardware from assembled unit. This will give you the subassemblies as they are shown on the following pages.

6

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The following photos are 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 #1

 

Item #2

 

Item #3

 

 

 

 

 

 

Driver Side Bench/Wall/

Passenger Side Rear Bench/Wall/

Front Bulkhead minus driver-side

Front bulkhead wing section

3rd Compartment Bulkhead

 

Wing section

Wing section

Item #4 & 13

 

Item #5

 

Item #7

 

 

 

 

 

 

 

(2) - Diamond plate floor

 

Center Divider

Driver-side ceiling

 

Item #8

 

Item #9

 

 

Item #10

 

 

 

 

 

 

 

Passenger-side rear ceiling

3rd compartment bulkhead

3rd Compartment bench w/ optional

 

 

 

 

 

storage door

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