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Havis-Shields Kwik-Kit KK-100-05 manual

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Table of contents for the manual

  • Page 1

    INSTALL INSTRUCTIONS KK-100-05 & KK-120-05 KWIK-KIT PRISONER TRANSPORT INSERT FORD and CHEVY VAN PR ISONER 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 Bi[...]

  • Page 2

    KK-XXX-05_INST_8-07 2 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 [...]

  • Page 3

    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 th e rear floor. The rear plastic floor trim on Chevy vans must be cut straight across as shown in phot o. Measure seven inches ( 7” ) straight line full wi dth. (Jig saw works well for[...]

  • Page 4

    KK-XXX-05_INST_8-07 4 Ford Van Driver-Side rear Ford Van Passenger-Side rear 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 ½” plywood or sound deadening m aterial. (Recommended). 4. If installing KK-F-VAK, (OEM air condi[...]

  • Page 5

    KK-XXX-05_INST_8-07 5 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-asse[...]

  • Page 6

    KK-XXX-05_INST_8-07 6 Remove all black hardw are from asse mbled unit. This will give you the subassemblies as they are shown on the follow ing pages.[...]

  • Page 7

    KK-XXX-05_INST_8-07 7 The following photos are the main subassemb lies as they are shipped from the factory. Remove drawing on final page and referen ce the item #’s as you install this kit. Driver Side Bench/Wall/ Front bulkhead wing section Item #1 Center Divider Item #5 (2) - Diamond plate floor Item #4 & 13 Passenger Side Rear Bench/Wall/[...]

  • Page 8

    KK-XXX-05_INST_8-07 8 Item #12 Rear bulkhead/door assembly Item #6 3 r d Compartment Bulkhead/door assembly Item #11 3 rd Compartment ceiling KWIK KIT LAYOUT Diamond plate floor and ceiling sections are not shown for detail purposes.[...]

  • Page 9

    KK-XXX-05_INST_8-07 9 VERY IMPORTANT: Be sure that all Auxiliary lighting, video systems, Kwik kit options, and wiring are complete. Access is s ever ely limited after kit is installed. For neatness of wiring, route all cables down driver-s ide “B” pillar. If going under hood for power to console, drill hole at location above. 1 ½” Hole “B[...]

  • Page 10

    KK-XXX-05_INST_8-07 10 Place Driver-side Bench/Wall assembly into van so bench rests on wheel well Item #1 Remove steel support bracket for Emergency Exit Hatch pin. Re-install when attaching Front Bulkhead to Bench/Wall assemblies Item #3 Place Passenger-side Bench/Wall assembly into van so bench rests on wheel well Item #2 Remove Emergency Exit H[...]

  • Page 11

    Item #4 & #13 Place (2) Diamond Plate Floors between Bench/Wall assemblies and Front bulkhead . Place cardboard along side of bench while positioning Be careful that exposed wires are not touching metal and optional KK- x-VAK hoses are not completely crushed Note: Vent hose will be tight in spot s. If hose are crushed to an oval shape the airfl[...]

  • Page 12

    KK-XXX-05_INST_8-07 12 Remove screws holding the center divider together where 3 rd Compartment Bulkhead will be mounted. Item #5 Position 3 rd Compartment Ceiling into vehicle. Item #12 Current view of installa tion Slide the ceiling sections out of the way in order to access A/C hoses, wires, etc. Note: These components will be ha rd to access on[...]

  • Page 13

    Re-install screws removed in step above and loosely attach aligning all three materials. Note: An awe or scribe is recommended to help align holes Item #9 to #5 Place 3 rd compartment bench Photo shows optional storage door Note: Be careful not to scratch bulkheads. Item #10 Bolt 3 rd Compartment Bench to 3 rd Compartment Divider using ¼” x ¾?[...]

  • Page 14

    KK-XXX-05_INST_8-07 14 Loosely bolt Rear Bulkhead Doorframe ( at the door hinge) to Bench/Wall assemblies using ¼” x ¾” carriage bolts, washers and serrated nuts Item #6 to #2 Place the 3 rd Compartment Doorframe assembly . Item #11 Loosely attach Doorframe to Center divider using #10 x 3/8” flat head machine screws and nylock nuts Item #6 [...]

  • Page 15

    KK-XXX-05_INST_8-07 15 An awe or scribe will help align the holes THE FOLLOWING STEPS AR E EXTREMLY CRITI CAL FOR A SUCCESFULL INSTALLATION! PLEASE FOLLOW THESE INSTRUCTIONS CAREFULLY. Item #1 Rear driver-side doorframe wing Position of driver-side Rear Doorframe when installing with factory rear air There should be at least ¼” of space between [...]

  • Page 16

    KK-XXX-05_INST_8-07 16 Top Passenger-Side rear Top Driver-Side rear 3” Item #6 With unit positioned acc ording to m easurements on previous page, pre - drill and attach a #10 x 1” sheet metal screw to hold the rear Bulkhead in place while assembling the remainder of the unit. Item #6 Item #6 Item #6 3” to 3 1/2” Item #7 to #1 Position Drive[...]

  • Page 17

    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. Pre-drill through Ceiling sections, (using Divider as a template), with 3/16” d rill bit and attach using ¼” x 1 ½” hex head lag bolts Item #5 through #8 into #7 Attach rema[...]

  • Page 18

    KK-XXX-05_INST_8-07 18 3/8” x 2” Hex head bolt, washers, and nut On the Rear doorframe , remove the sheet metal screws installed e arlier. 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 On 3 rd Compartment Doorfram[...]

  • Page 19

    Socket Ball Item #14 to doors and frames Attach Ball & Socket Style Doorstop. 1 st Attach “Ball” portion of assembly. Attach to threaded hole on the doo r using a ¼” x 1” Hex head bolt. nd 2 Attach the “Socket” and brack et portion. Attach to doorframe using #8 x ¾” Phillips machine screws and keps nuts. Silicone all seems and j[...]

  • Page 20

    KK-XXX-05_INST_8-07 20 Optional Storage Compartm ent (Sold Seperatley) FINAL INSTALLATION PHOTOS Optional Storage Compartm ent (Sold Separately)[...]

  • Page 21

    KK-XXX-05_INST_8-07 21 PT-VIDEO-X C-VS-1800-ECO w/ C-TCB-7 & C-3090-7 K K -RLL KK-PV ENT K R -CCL-1 KR-DL PRISONER TRANSPORT OPTIONS – (A ll SOLD SEPERATLEY )[...]

  • Page 22

    Item 3 Item 7 Item 1 Item 12 Item 5 Item 8 ITEM DESCRIPTION 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 Ceiling 8 Passenger-side Rear Ceiling 9 3 rd Compartment Bulkhead 10 3 rd Compartment Bench 11 3 rd Compartment Doorframe 12 3 rd Compartment Ceili[...]