Havis-Shields Kwik-Kit KK-100-03 Configuration guide

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
owered Drill
owered Screwdriver (recommended)
Drill Bit Set
Tape Measure
Screwdriver Set
Awe or Scribe
ry-bar
Wire Crimping tool
Wire Stripping tool
Wire Cutter
Circular Saw (for plywood)
Utility knife
Caulking gun
HARDWARE - 0” 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” hillips pan head sheet metal screw GSM33196 Floor/wall to ceiling
8 #8 x 3/8” hillips flat head screw GSM33179 Vent plates/dome lights
32 ¼” x ¾” hillips flat head machine screw GSM33078 Wall/Bench extension
25 ¼” x ¾” Hex head bolt GSM33001 3
rd
divider, 3
rd
ceiling
25 ¼” Flat washer GSM31005 3
rd
divider, 3
rd
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 RM97343 Seams & Gaps
4 Lock key RM97660-1 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

KK-XXX-03_INST_10-07
2
40” COMPARTMENT (cont):
QTY DESCRIPTION PART # USED FOR:
40 #10 x 1” hillips pan head sheet metal screw GSM33196 Floor, wall to ceiling
25 #8 x 3/8” hillips 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” hillips 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 [e-mail] or call 1-800-
524-9900.
 If this is your first time installing a Havis Shields Equipment Corp risoner 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.

KK-XXX-03_INST_10-07
3
Rear OEM Trim modifications
1997-2008 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 1/4”)
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***

KK-XXX-03_INST_10-07
4
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 ***
8”inches 8” inches
Ford Passenger-Side rear Ford Driver-Side rear
***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

KK-XXX-03_INST_10-07
5
1. Remove clear shrink-wrap covering from
prisoner transport assembly.
2. This is the 3
rd
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
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

KK-XXX-03_INST_10-07
6
Remove all black hardware from assembled unit. This will give you the
subassemblies as they are shown on the following pages.

KK-XXX-03_INST_10-07
7
VERY IMPORTANT:
Be sure that all Auxiliary lighting, video systems, Kwik kit options, and
wiring are complete Access is severely limited after kit is installed
If optional rear load light(s)
(KK-RLL) was ordered, install at
this time.
See KK-RLL install instructions
Run all wiring for dome lights, power
vents, video system, HVAC, etc. at
this time. Tie to existing OEM harness
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.
1 ½” Hole
“B” illar
If optional ower Vent(s)
(KK- VENT) was ordered, see
those instructions at this time for
necessary prep work that must be
done prior to installing Kwik Kit
Be sure to tape harnesses to roof in
approximate locations that
accessories are being installed in
Kwik kit. This will vary between
the different model kits.
At this time go to the KK- (x)-
VAK
install instructions. This must be
installed prior to Kwik Kit.
Notch trim
for wiring

KK-XXX-03_INST_10-07
8
lace
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
lace
Passenger
-
side
Bench/Wall
assembly into van so
bench rests on wheel well
Item #2
Remove
Emergency
Exit Hatch
from Front Bulkhead to ease
installation
Item #3
View of
Emergency Exit Hatch
support bracket assembled.
Item #3
lace
Front Bulkhead
into
vehicle
Item #3
Attach
Front Bulkhead
to
Driver-side Bench/Wall
assembly
Item #3

KK-XXX-03_INST_10-07
9
Current view of installation
lace Center Divider into vehicle.
Item #5
Item #4
Item #3
NOTE: Some installers
prefer to install ceiling
prior to divider
.
Item #5
Carefully place
Driver
-
side
Ceiling section into vehicle.
Item #7
Loosely bolt
Center Divider
to
Front Bulkhead
Item #5 to #3
lace (2)
Diamond Plate Floors
between Bench/Wall assemblies and
Front bulkhead. Place cardboard
along side of bench while positioning
the floor to avoid scratching the bench.
Item #4 & #13
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 spots If hose are crushed to an oval
shape the airflow will still be good Avoid completely crushing hoses
The floor(s) will square the be
nches
and bulkheads to the kit.

KK-XXX-03_INST_10-07
10
Item #9
Remove Bulkhead Emergency
Exit Hatches to ease installation.
Item #9
Route dome light wires, HVAC
hoses, video cables, etc to their
respective locations
Item #8
lace assenger-
side Ceiling section into
vehicle
Do not attach any hardware at this time
Item #8
osition Middle Bulkhead to
separate front and rear
compartments
Current view of installation
Slide the ceiling sections out of the way in order to access A/C hoses, wires, etc.
Note: These components will be hard to access once ceiling is mounted.
Remove all slack from hoses to maximize airflow
Item #7 & #8
Item #7 & #8
Item #12
Install forward compartment
driver sidewall / bench assembly.
Item 10.
Install forward compartment
ceiling assembly. Item 12.
lace rear facing bench against
front bulkhead. Item 16.
Item # 10
Item # 16

KK-XXX-03_INST_10-07
11
Rear Facing bench
Bolt side door and door-frame
assembly using ¼” x ¾” carriage
bolts, washers and nuts.
Loosely bolt assenger-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
Use under seat flange holes to mark
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.
Attach floor flange and side seat
flange with # 10 x ¾” pan head sheet
metal screws.
Drill floor flange and side seat
flange with a 5/32” drill bit.

KK-XXX-03_INST_10-07
12
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
lace 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
to #5
osition between
Driver and
Passenger-side Bench/Wall
assemblies
Item #6
lace
Rear Bulkhead
Doorframe into vehicle
Item #6
Align
3
rd
Compartment Doorframe
to
3
rd
Compartment Ceiling and loosely
attach ¼” x ¾” hex head bolts, washers
and serrated nuts.
Item #12 to #11
ress doorframe to align with holes in
Passenger-side Bench/Wall
assembly.
Item #11
to #9
Note: It is recommended to put
edge molding on the EM door
opening on the passenger side to
avoid damaging the Kwik kit
door.

KK-XXX-03_INST_10-07
13
An awe or scribe will help
align the holes
THE FOLLOWING STEPS ARE EXTREMLY CRITICAL FOR A SUCCESFULL
INSTALLATION! PLEASE FOLLOW THESE INSTRUCTIONS CAREFULLY.
Item #1
Rear driver-side
doorframe wing
osition of driver-side
Rear
Doorframe when installing with
factory rear air
There should be at
least ¼” of space between the
A/C blower motor and wing
8”inches
Lower Driver-Side rear
Measurement from driver-side
Rear Doorframe to vehicle
doorframe shown above
8” inches
Lower Passenger-Side rear
Measurement from passenger-side
Rear Doorframe to vehicle
doorframe shown above
Cut door gasket with utility knife. Cut gasket to the length
of door acceptor frame. Attach as shown above.
osition the entire unit according to the
measurements on the following page.
Note: Maneuver the kit into position
Tighten screws holding
Rear
Doorframe to Center Divider
Item #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
Item #7, #8, #12 to #3, & #6
¼”
ry bar

KK-XXX-03_INST_10-07
14
osition
Driver
-
side Ceiling
section to
mate with Bench/Wall assembly. re-
drill 5/32” holes into Ceiling, using
Bench/Wall assembly holes as a guide.
Item #7 to #1
3” inches
Top Passenger-Side rear
Approximately 3”inches
Top Driver-Side rear
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
in
place while assembling the remainder of the unit.
Item #6 Item #6

KK-XXX-03_INST_10-07
15
Begin to tighten
ALL
loose hardware on the remainder of the unit,
b
eing sure to align edges and bends of materials being tightened. This
will square the unit to itself.
re-drill through
Ceiling
sections, (using
Divider as a template), with 3/16” drill
bit and attach using ¼” x 1 ½” hex head
lag bolts
Item #5 through #8 into #7
Attach remainder of
Diam
ond plate floor.
re-drill
diamond floor (only) w/ 3/16” hole and 1/8” hole through
floor of vehicle
Item #4 through #1 into van floor
Item 4 through #1 into van floor
Attach to wood floor or rubber
floor mat using #10 x 1” hillips
pan head sheet metal screws
Through Item #4, #1, & van floor
Be Sure Floor Is Square To
Benches
&
Bulkheads.
Attach Divider to vehicle. re-drill through floor(s)
using 3/16” drill bit and attach using ¼” x 1 ½” hex
head lag bolts
Item #5 & #4 to van floor
re-drill ceiling with 5/32” drill bit and attach #10 x
1” hillips pan head sheet metal screws to hold
Ceiling to Bench/Wall assembly. Repeat these steps
on the Passenger-side Ceiling section
Item #8 to #2
Be careful when pre-
drilling not to hit
hoses, wires, etc…
Note: Ceiling is behind wall

KK-XXX-03_INST_10-07
16
3/8” x 2” Hex head
bolt, washers, and nut
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.
Item #6 to van floor
On
3
rd
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.
Item #11 to van floor
Item #11 to van floor
Attach the doorframe to the vehicle
using #10 x 1” hillips pan head sheet
metal screws
Item #11
Secure the
Front Bulkhead
. Drill (2- one
per-side) 3/8” holes through the frame, ½”
p
lywood, and floor of vehicle Attach using
3/8” x 2” hex head bolt, flat washer, fender
washer, and nut.
3/8” x 2” hex head bolt, flat washer,
fender washer, lock washer, and nut
Item #3 to van floor

KK-XXX-03_INST_10-07
17
Silicone all seems
and joints. This will
allow the unit to be
hosed out.
In the upper corner of each side
of the 3
rd
Compartment
Doorframe are small filler
panels that need to be installed.
Attach using ¼” x ¾” carriage
bolts, washers, and serrated
nuts.
Item #11
lace trim panels as shown above
re-
drill through trim panel (only)
with 3/16”. re-drill the vehicle
w/ 1/8” hole and attach panels
using #10 x 1” sheet metal screws
Item #15
Attach Ball & Socket Style Doorstop.
1
st
Attach “ in” portion of assembly. Attach to threaded hole on the door using a ¼” x 1” Hex
head bolt.
2
nd
Attach the “Socket” and bracket portion. Attach to doorframe using #8 x ¾” hillips machine
screws and keps nuts.
Item #14 to doors and frames
in
Socket

KK-XXX-03_INST_10-07
18
FINAL INSTALLATION PHOTOS
Optional Stora
ge Compartment
(Sold Separately)
Forward Compartment for models
KK-100-03, KK-100-04, KK-120-03 and KK-120-04

KK-XXX-03_INST_10-07
19
T-VIDEO-X
C-VS-1800-ECO w/
C-TCB-7 & C-3090-7
KK
-
RLL
KK- VENT
KR
-
CCL
-
1
KR-DL
PRISONER TRANSPORT OPTIONS – (All S LD SEPERATLEY)

ITEM DESCRIPTION
1 Driver-side Bench/Wall 2 assenger-side Bench/Wall 3 Front Bulkhead 4 Diamond-plate Floor 5 Divider 6 Rear Bulkhead/ Doorframe 7 Driver-side Rear Ceiling 8 assenger-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 7
Item 8
Item 1
Item
Item 2
Item 3
Item 4
Item 9
Item 11
Item 12
Item 14
Item 15
Item 14
Item 13
Item 10