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INSTALL INSTRUCTIONS KK-100-03 & KK-120-03
KWIK-KIT PRISONER TRANSPORT INSERT
FORD and CHEVY VAN PRISONER TRANSPORT
TOOLS REQUIRED:
¼” & 3/8” Ratcheting Wrenches
¼” & 3/8”Air Ratchets (recommended)
3/8” Impact Guns (recommended)
¼” & 3/8” Standard Socket Sets
Powered Drill
Powered Screwdriver (recommended)
Drill Bit Set
Tape Measure
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
Awe or Scribe
Pry-bar
Wire Crimping tool
Wire Stripping tool
Wire Cutter
Circular Saw (for plywood)
Utility knife
Caulking gun
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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!
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
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.
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:
••••
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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KK-XXX-03_INST_10-07
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similar in Ford and Chevy Vans.
step)
After plastic trim is cut and back in
parts
Note: With OEM rear AC/Heat,
The kit will be shifted to passenger
1997-2008 Chevrolet G-Series Van
Rear OEM Trim modifications
Installation of Kwik Kit is very
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
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
fit into the correct locations.
side.
.
*** Ford Van does NOT require
rear trim modification***
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KK-XXX-03_INST_10-07
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all rear trim and headliner as this will aid in sound deadening & insulation
Ford Driver-Side rear
Ford Passenger-Side rear
8”inches
3. PASSENGER WINDOW VAN PREPARATIONS:
8” inches
***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
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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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
1. Remove clear shrink-
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.
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VERY IMPORTANT:
Be sure that all Auxiliary lighting, video systems, Kwik kit options, and
Run all wiring for dome lights, power
done prior to installing Kwik Kit
Be sure to tape harnesses to roof in
the different model kits.
VAK
for wiring
wiring are complete. Access is severely limited after kit is installed.
Notch trim
If optional rear load light(s)
(KK-RLL) was ordered, install at
this time.
See KK-RLL install instructions
approximate locations that
accessories are being installed in
Kwik kit. This will vary between
vents, video system, HVAC, etc. at
this time. Tie to existing OEM harness
At this time go to the KK- (x)-
install instructions. This must be
installed prior to Kwik Kit.
“B” Pillar
For neatness of wiring, route all
cables down driver-side “B” pillar.
If going under hood for power to
console, drill hole at location above.
If optional Power Vent(s)
(KK-PVENT) was ordered, see
those instructions at this time for
necessary prep work that must be
1 ½” Hole
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Driver
-
side Bench/Wall
Item #1
install
Passenger
-
side
assembly into van so
Emergency
Exit Hatch
Emergency Exit Hatch
Front Bulkhead
Front Bulkhead
Item #2
Place
assembly into van so bench rests
on wheel well
Place
Bench/Wall
bench rests on wheel well
Item #3
Remove steel support bracket for
Emergency Exit Hatch pin. Re-
when attaching Front Bulkhead to
Item #3
Remove
from Front Bulkhead to ease
installation
Bench/Wall assemblies
Item #3
Place
vehicle
into
Item #3
Attach
Driver-side Bench/Wall
assembly
Item #3
to
View of
support bracket assembled.
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Place Center Divider into vehicle.
prior to divider
.
Driver
-
side
Center Divider
Diamond Plate Floors
the floor to avoid scratching the bench.
KK
-
Note: Vent hose will be tight in spots. If hose are crushed to an oval
shape the airflow will still be good. Avoid completely crushing hoses.
nches
Item #4 & #13
Be careful that exposed wires are not touching metal and optional
x-VAK hoses are not completely crushed
Item #5
Item #3
Item #4
The floor(s) will square the be
and bulkheads to the kit.
Place (2)
between Bench/Wall assemblies and
Front bulkhead. Place cardboard
along side of bench while positioning
Item #5
NOTE: Some installers
prefer to install ceiling
Item #5 to #3
Loosely bolt
Front Bulkhead
to
Current view of installation
9
Item #7
Carefully place
Ceiling section into vehicle.
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side Ceiling section into
Item #8
Slide the ceiling sections out of the way in order to access A/C hoses, wires, etc.
Item #8
Place Passenger-
vehicle
Do not attach any hardware at this time
Route dome light wires, HVAC
hoses, video cables, etc to their
respective locations
Item #7 & #8
Item #7 & #8
Note: These components will be hard to access once ceiling is mounted.
Remove all slack from hoses to maximize airflow.
Current view of installation
Item #9
Remove Bulkhead Emergency
Exit Hatches to ease installation.
Item #12
Item #9
Item # 10
Position Middle Bulkhead to
separate front and rear
compartments
10
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.
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Use under seat flange holes to mark
flange with # 10 x ¾” pan head sheet
Rear Facing bench
Attach floor flange and side seat
metal screws.
and Drill through front bulkhead
with ¼” bit. Use ¼” x ¾” bolts and
serrated to attach seat to bulkhead.
Attach seat cover plate with # 10 x
½” flat head sheet metal screws.
Drill floor flange and side seat
flange with a 5/32” drill bit.
Loosely bolt Passenger-side rear ceilings, Bench/Wall
assembly to Middle Bulkhead using ¼” x ¾” Carriage bolts
and serrated nuts
Note: An awe or scribe is recommended to help align holes.
Item #9 to #2
11
Bolt side door and door-frame
assembly using ¼” x ¾” carriage
bolts, washers and nuts.
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Rear Bulkhead
at the door hinge) to
assemblies using ¼”
3rd Compartment
Doorframe
Center
Item #6
to #5
Driver and
Rear Bulkhead
3rd Compartment Doorframe
to
Press doorframe to align with holes in
Item #6
Place
Doorframe into vehicle
Item #6 to #2
Loosely bolt
Doorframe (
Bench/Wall
x ¾” carriage bolts, washers and
serrated nuts
Item #6
Position between
Passenger-side Bench/Wall
assemblies
Note: It is recommended to put
edge molding on the OEM door
opening on the passenger side to
avoid damaging the Kwik kit
door.
Loosely attach
to
divider using #10 x 3/8” flat head
machine screws and nylock nuts
Item #11
Place the
Doorframe assembly.
Item #11
to #9
Passenger-side Bench/Wall
assembly.
12
Item #12 to #11
Align
3rd Compartment Ceiling and loosely
attach ¼” x ¾” hex head bolts, washers
and serrated nuts.
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Rear
There should be at
Position the entire unit according to the
Rear
Item #6
Item #7, #8, #12 to #3, & #6
to #5
Continue around the entire kit bolting
all Ceiling pieces to Bulkheads and
Doorframes using ¼ x ¾” carriage
bolts, washers, and serrated nuts
Cut door gasket with utility knife. Cut gasket to the length
of door acceptor frame. Attach as shown above.
An awe or scribe will help
align the holes
Tighten screws holding
Doorframe to Center Divider
Pry bar
measurements on the following page.
Note: Maneuver the kit into position.
THE FOLLOWING STEPS ARE EXTREMLY CRITICAL FOR A SUCCESFULL
INSTALLATION! PLEASE FOLLOW THESE INSTRUCTIONS CAREFULLY.
Item #1
Rear driver-side
doorframe wing
¼”
Position of driver-side
Doorframe when installing with
factory rear air
least ¼” of space between the
A/C blower motor and wing
Lower Driver-Side rear
8”inches
Measurement from driver-side
Rear Doorframe to vehicle
doorframe shown above
Lower Passenger-Side rear
8” inches
Measurement from passenger-side
Rear Doorframe to vehicle
doorframe shown above
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Driver
-
side Ceiling
in
Top Driver-Side rear
Top Passenger-Side rear
Item #6
Approximately 3”inches
3” inches
Item #6
With unit positioned according to measurements on previous page, pre-
drill and attach a #10 x 1” sheet metal screw to hold the rear Bulkhead
place while assembling the remainder of the unit.
Item #6
14
Item #7 to #1
Position
mate with Bench/Wall assembly. Pre-
drill 5/32” holes into Ceiling, using
Bench/Wall assembly holes as a guide.
KK-XXX-03_INST_10-07
section to
Page 15
ALL
eing sure to align edges and bends of materials being tightened. This
Ceiling
Diam
ond plate floor.
diamond floor (only) w/ 3/16” hole and 1/8” hole through
Benches
Bulkheads.
Be careful when pre-
Note: Ceiling is behind wall
drilling not to hit
hoses, wires, etc…
Item #8 to #2
Pre-drill ceiling with 5/32” drill bit and attach #10 x
1” Phillips pan head sheet metal screws to hold
Ceiling to Bench/Wall assembly. Repeat these steps
on the Passenger-side Ceiling section
Item #5 through #8 into #7
Pre-drill through
sections, (using
Item #4 through #1 into van floor
Divider as a template), with 3/16” drill
bit and attach using ¼” x 1 ½” hex head
lag bolts
Be Sure Floor Is Square To
Attach Divider to vehicle. Pre-drill through floor(s)
using 3/16” drill bit and attach using ¼” x 1 ½” hex
Attach remainder of
floor of vehicle
Item #5 & #4 to van floor
&
head lag bolts
Item 4 through #1 into van floor
Pre-drill
Through Item #4, #1, & van floor
Attach to wood floor or rubber
floor mat using #10 x 1” Phillips
Begin to tighten
b
pan head sheet metal screws
15
loose hardware on the remainder of the unit,
will square the unit to itself.
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Rear doorframe
sheet metal screws installed earlier. Drill
head bolts, washers, fender washers, lock
3rd Compartment Doorframe
Rear Doorframe.
Front Bulkhead
lywood, and floor of vehicle Attach using
3/8” x 2” hex head bolt, flat washer, fender
Item #11 to van floor
Item #6 to van floor
3/8” x 2” Hex head
bolt, washers, and nut
On the
, remove the
3/8” holes through the doorframe, floor,
and vehicle. Attach using 3/8” x 2” hex
washers, and hex nuts.
On
repeat the same steps done on
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,
fender washer, lock washer, and nut
Item #11
Attach the doorframe to the vehicle
using #10 x 1” Phillips pan head sheet
Item #3 to van floor
Secure the
per-side) 3/8” holes through the frame, ½”
p
metal screws
Item #11 to van floor
Only one bolt
. Drill (2- one
16
washer, and nut.
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In the upper corner of each side
Item #11
Place trim panels as shown above
drill through trim panel (only)
Socket
Pin
Item #14 to doors and frames
Attach Ball & Socket Style Doorstop.
1st Attach “Pin” portion of assembly. Attach to threaded hole on the door using a ¼” x 1” Hex
head bolt.
2nd Attach the “Socket” and bracket portion. Attach to doorframe using #8 x ¾” Phillips machine
screws and keps nuts.
of the 3rd Compartment
Doorframe are small filler
panels that need to be installed.
Attach using ¼” x ¾” carriage
bolts, washers, and serrated
Item #15
Pre-
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.
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FINAL INSTALLATION PHOTOS
ge Compartment
Forward Compartment for models
KK-100-03, KK-100-04, KK-120-03 and KK-120-04
18
Optional Stora
(Sold Separately)
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KK-RLL
KR-CCL
-
1
KK-PVENT
PRISONER TRANSPORT OPTIONS – (All
KR-DL
SOLD SEPERATLEY)
C-VS-1800-ECO w/
C-TCB-7 & C-3090-7
PT-VIDEO-X
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Item 10
1 Driver-side Bench/Wall
2 Passenger-side Bench/Wall
3 Front Bulkhead
4 Diamond-plate Floor
5 Divider
6 Rear Bulkhead/ Doorframe
7 Driver-side Rear Ceiling
8 Passenger-side Rear Ceiling
9 Separator Bulkhead
10 Front Compartment “L” Bench
11 Front Compartment Doorframe
12 Front Compartment Ceiling
13 Front Compartment Floor
14 (2) Door Stops
15 Diamond-plate floor filler panel
ITEM DESCRIPTION
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