INSTALL INSTRUCTIONS KK-100-06 & KK-120-06
TOOLS REQUIRED: |
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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 |
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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: |
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|
|
QTY |
DESCRIPTION |
PART # |
USED FOR: |
90 |
¼” x ¾” Carriage bolt |
GSM32000 |
|
90 |
¼” Serrated nut |
GSM30023 |
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40” COMPARTMENT (cont): |
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|
|
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 |
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.
2 |
KK-XXX-06_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 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 |
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8” inches |
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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 ***
4 |
KK-XXX-06_INST_8-07 |
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
5 |
KK-XXX-06_INST_8-07 |
Remove all black hardware from assembled unit. This will give you the subassemblies as they are shown on the following pages.
6 |
KK-XXX-06_INST_8-07 |
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
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Item #2 |
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Item #3 |
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Driver Side Bench/Wall/ |
Passenger Side Rear Bench/Wall/ |
Front Bulkhead minus driver-side |
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Front bulkhead wing section |
3rd Compartment Bulkhead |
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Wing section |
Wing section
Item #4 & 13 |
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Item #5 |
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Item #7 |
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(2) - Diamond plate floor |
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Center Divider |
Driver-side ceiling |
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Item #8 |
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Item #9 |
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Item #10 |
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Passenger-side rear ceiling |
3rd compartment bulkhead |
3rd Compartment bench w/ optional |
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storage door |
7 |
KK-XXX-06_INST_8-07 |