FI-0083 Toyota Land Cruiser 79 Series Tub Body External ROPS Rev B

AUS.RHD.1HZ:S65510102S

14/10/2011 - Rev B - Fitting InstructionsPage 1 of 26

1HZ - Leaf Sprung ®

ToyoTa LandCruiSer 79 SerieS Tub body

QTY

26

M12 x 30MM Hex Head

QTY

38

M12Hardened Flat WasHer

QTY

2

M12spring WasHer

QTY

24

M12nyloc nut

QTY

4

M12 x 35MM HalF cap screW

QTY

4

M12 sHakeprooF WasHer

QTY

22

M10 x 30MM Hex Head

QTY

44


QTY

22

M10nyloc nut

QTY

2

M16 x 90MM Hex Head

QTY

4


QTY

2

M16nyloc nut

QTY

6

M8 x 30MM Hex Head

QTY

18

M8Flat WasHer

QTY

6

M8spring WasHer

QTY

4

M8nyloc nut

QTY

4

M8serrated Flange nut

QTY

4

M8 x 80MM Hex Head

QTY

8

M6 x 20MM Hex Head

QTY

32

M6Flat WasHer

QTY

16

M6spring WasHer

QTY

16


QTY

8

M6 x 20MM doMe Head

QTY

20

3.7MMspacer disc (tHrust)

QTY

1

rops cell

QTY

2

rear stay

QTY

2

Front cHassis Bracket

QTY

2

rear cHassis Bracket

QTY

2

rear support Bracket

QTY

2

internal cHassis Bracket

QTY

2

rear coMpensator plate

QTY

1

spare WHeel Base

QTY

1

reverse Beeper Bracket

QTY

2

HigHligHt guard

QTY L+R

Floor triM teMplate

QTY

3

4MMrivet

QTY

1

installer’s coMpliance plate

QTY

1

saFety cell sticker

QTY

1

saFety cell durolens

QTY

4

150-0190Bush

QTY

2

150-0190Crush Tube

QTY

2

M16 x 90MM Hex Head

parTS SuppLied

paCking CHeCk-off

SeriaL number:paCked by: daTe: / /CHeCked by: daTe: / /

Fitting Instructions - Rev B - 14/10/2011 Page 3 of 26


1HZ -Leaf Sprung®


ExtERnaL RoLL ovER PRotEction

FittinG inStRUctionS

FI-0083





Pre InstallationEnsure that the Product Number on the Fitting Instruction document matches that on the product’s packaging.Verify that the VIN number of the vehicle matches the VIN number on the job card.EnsurethatthevehicleairbagconfigurationiscompatiblewiththeROPSasspecifiedonthemanu-facturers’plate.RefertoAppendixAforillustrationsofairbagconfigurations.Check the functionality of the vehicle electrical system.CheckvehicleforSideCurtainAirBagsifthevehicledoes,checktheROPSarecompatible.If the vehicle is to be road registered advise your signatory for Engineering and Compliance. NotificationregardingROPSinstallation,Seatbeltrelocation,Seatingcapacityreductionetc.Checkthatallkitcontentsarepresent–refertothefittinginstructionsAllpaintworkandinternaltrimmustbeprotectedtopreventdamageduringROPSinstallation.EnsurethatthereisnowiringtogounderthehoodliningbeforetheROPSisinstalledi.e.Highlights or emergency lighting.Checkthelocationofwiringlooms,fuellines,brakelines,airconditioninglinesandancillaryproductspriortobeginninginstallation(Checkunderthefloorandundercarpet)Do you have all of the required tools for installation inc appropriate eye and hearing protection (PPE)?

Post InstallationHastheROPSbeeninstalledusingthesuppliedfittingkit?Areallbolts,nutsandtubejoinersappropriatelytightened?Doallboltshaveaminimumoftwothreadsshowingthroughthenut?Haveallfastenersbeensecuredtothespecifiedtorquesettings?Havealltightenedboltshadtorquepaintapplied?Ensure that all the star nuts on the load guard are tightened in sequence.Checkthatwiringlooms,brakelinesandfuellinesarenotcrimped,cutorrestrictedbytheROPS.Checkthatotherancillaryproductssuchasfuelfillerreleasecableswork.Checkthatallrearvehiclelightingisworkingcorrectly.Doallseatbeltsworkcorrectly?(Checknobeltsarestuckunderseats)Haveallcovertrims,carpetsandmatsbeenrefittedcorrectly?Isallpaddingfittedinthecorrectpositionandsecured?Areallsharpedgesremovedfromzipties?Istheloadguard/loadrestraint/loadboxpresentandsecuredappropriately?(Notpresentonallmodels–refertokitcontents)AreallwarningdecalsandtheSafetyCellIDtagappliedtotheROPS?HasalllocalTransportAuthorityCompliancingbeencompletedincludinganyrequiredseatingreduction?

Final InspectionThisROPSisinstalledcorrectlyasperthefittinginstructionsTestdrivethevehicletoensurethatthevehicleisfullyfunctionalandthattherearenorattlesorsqueaks present.LogontotheE-Portalhttp://www.minecorp.com.au/&completetheE-TraceRecord

inSTaLLaTion CHeCkLiST



1HZ -Leaf Sprung®


• ReadthroughthefittinginstructionsbeforeattemptingtoinstalltheROPSassembly,failingtodosomaycausedamagetothevehicleorROPSassembly.

• It is recommended that the installation be performed by a Licenced Fitter at an accredited Minecorp fitmentcentre.

• Designedforusewith2009modelonwards4.2Litre6CylinderDiesel(1HZ),ToyotaLandCruiser79SeriesTubBody(LeafSprung).

• FitmenttestedonRightHanddrivemodelsonly• GenericDefinitionsatendofdocument• Installation Checklist at front of document• ItisrecommendedtouseaHandratchetspanner(notanairratchet)toavoidstrippingcriticalfactorynuts

andbolts(e.g.seatbeltboltsthathavetoberemovedthenrefittedintoafactorythreads)

3.5 hours

produCT overview

generaL noTeS

fiTTing Time





QTY

26

M12 x 30MM Hex Head

QTY

38


QTY

2

M12spring WasHer

QTY

24

M12nyloc nut

QTY

4

M12 x 35MM HalF cap screW

QTY

4

M12 sHakeprooF WasHer

QTY

22

M10 x 30MM Hex Head

QTY

44


QTY

22

M10nyloc nut

QTY

2

M16 x 90MM Hex Head

QTY

4


QTY

2

M16nyloc nut

QTY

6

M8 x 30MM Hex Head

QTY

18

M8Flat WasHer

QTY

6

M8spring WasHer

QTY

4

M8nyloc nut

QTY

4


QTY

4

M8 x 80MM Hex Head

QTY

8

M6 x 20MM Hex Head

QTY

32

M6Flat WasHer

QTY

16

M6spring WasHer

QTY

16


QTY

8

M6 x 20MM doMe Head

QTY

20

3.7MMspacer disc (tHrust)

QTY

1

rops cell

QTY

2

rear stay

QTY

2


QTY

2

rear cHassis Bracket

QTY

2


QTY

2

internal cHassis Bracket

QTY

2


QTY

1

spare WHeel Base

QTY

1


QTY

2

HigHligHt guard

QTY L+R

Floor triM teMplate

QTY

3

4MMrivet

QTY

1


QTY

1

saFety cell sticker

QTY

1


QTY

4

150-0190Bush

QTY

2

150-0190Crush Tube

QTY

2

M16 x 90MM Hex Head

Flange nut & panel Flange nut & plate Factory tHread Welded nut nutsert nyloc nut

Fastener conFigurations

spr

ing W

asH

erH

ar

d F

lat

Wa

sHer

Ha

rd F

lat

Wa

sHer

parTS SuppLied



1HZ -Leaf Sprung®


plastic protective FilM torque seal paintveHicle toucH up

paint

• Removekeyfromvehicleignitionanddetachnegativeterminalonvehicle’sbattery.• BesuretocomplywithyouworkshopsafetystandardswhileinstallingtheROPSassembly.• Worksafelyatalltimesandpropersafetyequipment(PPE)mustbeworn.

Flange nut & panel Flange nut & plate Factory tHread Welded nut nutsert nyloc nut

Fastener conFigurations

spr

ing W

asH

erH

ar

d F

lat

Wa

sHer

Ha

rd F

lat

Wa

sHer

TooLS required

required ConSumabLeS

faSTener ConfiguraTionS

Hex drive set (Metric)Metric socket ratcHet set

18MM socket 17MM socket 24MM socket extension arM set

torque WrencH 5-145nM Metric spanner set drill rivet gun tape Measureside cutters

SafeTy noTeS





• RemovetheBrakefluidlinebracket(RHsidejustforwardofthegreenfuelmanagementsystem)

• Remove breather pipe bracket (RH side justforwardofthegreenfuelmanagementsystem)

• Remove wiring loom bracket (RH side justforwardofthegreenfuelmanagementsystem)

STep1.

STep2.

STep3.



1HZ -Leaf Sprung®


• Removefuellinebracket(RHsidejustforwardofthegreenfuelmanagementsystem)

• RemoveforwardRHbrakelinebracket

• RemoveforwardRHwiringloombracket

STep4.

STep5.

STep6.





• RemovetheforwardRHsidefuellinebracket

• RemoveforwardLHsidefuellinebracket

• Removetheexhaustjoinboltsundercab

STep7.

STep8.

STep9.



1HZ -Leaf Sprung®


• Removefrontexhaustpipefleximountnuts

Removeexhaustjoinatthemufflerend

Removerearexhaustpipefleximountnuts

STep10.

STep11.

STep12.





• Using a hammer tap the chassis spacers into place ontheFrontChassisClampBrackets(Spacerstofaceinside)

• Carefullyliftmuffleroffrubbermountingbracketandlowerthemufflerendtotheground.(Leavethemostrearrubbermountbolted)

• Carefullyremoveforwardexhausttubesection

Lever the LH side fuel line bracket out from thechassisrailbyapproximately6mm

*Torque Settings Table at end of Document

nb. due to the large variation in OEM chassis rail widths, supplied are a variety of spacer sizes, you may find that you require none, some or all of the spacers depending on the particular vehicle you are fitting the ROPS to. To check; measure between the inside of the chassis rails, and between the outsides of the brackets on the ROPS Cell, take the difference, half it and that is the thickness of spacers you require be sure to leave 1 or 2mm a side for ease of fitment.

caution

8x

STep13.

STep14.

STep15.



1HZ -Leaf Sprung®


STep16.

STep17.

STep18.

• Using a hammer tap the chassis spacers into place on the Inner Chassis Brackets (Spacers to faceinside)

8x

• Alignthetrimtemplatewiththeexistingholesinthetrayandcutthespecifiedareaasmarked.

• Removethefloorhatchfromthetubandthefour8mmbolts(1infrontofthehatchand3behindthehatch).

Note the orientation of the template in relation to thefrontofthevehicleandtheRighthandsideand Left hand side of the the vehicle

!

QTY L+R

Floor triM teplate





• Remove the tub mounting bolt from the fronttowerpost.

• Usinga trimremoval tool, release theaccessoryclipsontheauxiliarypowerlineontheRHsidenexttothefrontROPSchassisclamplocationthatis running to the fuel management system.

• Place the internal Chassis brackets on the chassis between the vehicle cabin and the first towermount.

STep19.

STep20.

STep21.

QTY

2

inner cHassis Bracket



1HZ -Leaf Sprung®


• Place the Chassis clamping bracket over the chassis ensuringthetoweriscoveredbythebracket.

• BoltthebrackettotheinternalbracketusingM12x30mmhexheadbolts,washersandaNylocNut.

• Thetowerholesonlyhaveonewashereachontheoutside.

12xM12 x 30mm

STep22.

STep23.

STep24.

QTY

2


• Inserta12x30mHexHeadBoltwithaSpringwasherandaflatwasherthroughthetubmountinghole and bolt into the top of the chassis clamping bracket.

2x

M12 x 30mm

• PlacetheMainHoopAssemblyOverthetubandslide it over the Chassis clamp brackets.

QTY

1

rops cell





• Using a hammer tap the chassis spacers into place ontheRearChassisClampBrackets(Spacerstofaceinside)

• Remove the existing bolts from the tub crossmember above thewheels (by the second towermount.)

• FittheRearChassisBracketsoverthechassisandintothesecondtowermount.

• Drill throught the factory threads and the tub cross memberusinga10mmbit.

AligntheholesandbolttogetherusingtheM12x30mmHex boltswith onewasher on each bolt and anyloc nut.

4x

12x

M12 x 30mm

Drill

4x

STep25.

STep26.

STep27.

QTY

2




1HZ -Leaf Sprung®


• Drillholesthroughthetubusinga12mmdrillbitwhilstusingthebracketasaguide.

• Deburr the hole from the top and bottom.

• Bolt the Bracket welded to the Main HoopAssembly into the existing factory thread in thefloorofthetub,

• UseaM8x30mmHexHeadbolt,springwasherandflatwasher.

• FittheRearChassisBracketsoverthechassisandintothesecondtowermount.

• Bolttheupperpartofthebrackettothetubcrossmember(throughthedrilledholes)usingtheM8x 80mm Hex Head Bolts, Spring Washer, FlatWashersandaserratedflangenut.

M8x30mmHexHead

4x

M8 x 80mm

2x

M8 x 30mm

Drill

4x

STep28.

STep29.

STep30.





• Debur the holes top and bottom.• BolttheRearsupportbracketthroughthedrilled

holesusingM10x30mmBolts.

• Place the rear support bracket into the tub aligning theholeswiththeexistingthreadsinthetub.

• Drillout twoholesdiagonallyacrosseachotherusinga12mmdrillbit.

4x

M10 x 30mm

Drill

14x

STep31.

STep32.

QTY

2


STep33.

• Bolt the Bracket welded to the Main HoopAssemblythroughthedrilledholes,usingM10x30mmBolts,FlatwashersandaNylocnut.

4x

M10 x 30mm



1HZ -Leaf Sprung®


• Drilltheholesthroughthetubusinga12mmdrillbit and the rear support bracket as a guide.

• Unblotthetwoboltsfromthebracket.• Debur all the holes top and bottom.

• BoltdownthroughtheRearSupportBracketandthefloorusingM10x30HexHeadBoltsandaflatwashersandaNylocnut.

• TorqueboltstothespecifiedTorquesettings.

• Bolt through the top holes of the Rear SupportBracketandthewheelarchusingM10x30HexHeadBoltsandaflatwasher,RearCompensatorPlate,FlatWasherandNylocnut.

• TorqueboltstothespecifiedTorquesettings.

4x

M10 x 30mm

14x

M10 x 30mm

Drill

14x

STep34.

STep35.

STep36.

QTY

2






STep37.

• Fit the existing Spare wheel bracket on to theROPS using the remainingM6 hex head bolts,washersandSerratedFlangeNut.

8x

M6 x 20mm

STep38.

STep39.

• Fitthecouplingbolts(M12x35HalfCapscrew)includingtheShakeproofWashers.

• TorqueboltstothespecifiedTorquesettings.• Applytorquepainttoalltorquedbolts.

4x

M10 x 35mm

• FittheRearStaysintoplacebyboltingtheM16Bolt,WashersandNylocNut.

2x

M16 x 90mm

QTY

2

rear stay



1HZ -Leaf Sprung®


• BoltintoplaceusingM8x30mmHexHeadbolts,flatwashersandaSerratedFlangeNut.

• PlacetheSpareWheelbaseplateovertheexistingtire supports.

• Spacetheplate150mmfromtheheadboard.• DrilltheholesusinganM10drillbit.

• BolttheProtectorcoversusingM6x20mmDomehead Bolts, Flat washers, a Springwasher andSerratedFlangeNut.

150mm

4x

M8 x 30mm

8x

M6 x 20mm

STep40.

STep41.

STep42.

QTY

2

HigHligHt guard

HEA

DBOARD

Drill

4x

QTY

1

spare WHeel Base





STep43.

STep44.

STep45.

• Engrave the supplied compliance platewith theVehicle and Installer information.

• AttachtheplatetothelegoftheROPSCellusingthe supplied rivets.

FilloutSafetyCellInstallationRecordtriplicateform,storethewhitepageintheVehicle’sglovebox,keeptheyellowformforyourrecordsandreturnthebluecopytoMinecorpHeadoffice(POBox363,AcaciaRidge,QLD).

Manufacturer Warranty VOID if NOT Completed

3x

4mm

QTY

1


• Fill out the Installation Checklist at the front of this document and submit it to Minecorp through youre-portal.



1HZ -Leaf Sprung®


• Apply the Safety Cell Durolens sticker to theVehicle’srearwindow.

STep46.

reverSe aLarm braCkeT

QTY

1


• Note:thereversealarmbracketfitsundernieththebeacon bracket and utilises the same mounting points as the beacon.

QTY

1






Bolt Torque Table

NominalSize&ThreadPitch

Hex Head Nutsert Half Cap Button Head

Bolt Torque Specifi cation: Nm / ft lbfM10x1.50 44Nm/32ftlbf 27Nm/20ftlbf 44Nm/32ftlbf 44Nm/32ftlbfM12x1.75 74Nm/54ftlbf 88Nm/65ftlbfM16x1.75 142.2Nm/105ftlbf

RHS - Right Hand Side

LHS - Left Hand Side

FRO

NT

BA

CK

a-pillarB-pillarc-pillard-pillar

caB cHassisdual caB / creW caB

van/Mini Bus Wagon

single caB caB cHassis

caB cHassisextra/space/king caB

e-pillar

TorquePaintPPE

ROPSRighthand

Left handBonnet

-Paintusedtoindicatedaboltornutisatthedesiredtorqueandhasnotbeentamperedwith.-PersonnelProtectiveEquipment-RollOverProtectionSystem-Righthandsidewhenlookingforwardfromtherearofvehicle-Lefthandsidewhenlookingforwardfromtherearofvehicle-Enginebayhood

generiC definiTionS

14/10/2011 - Issue: 1

S65510102S

Phone australia: 1300 922 881 Phone international: +61 1300 922 881

Web: minecorp.com.aueMail: [email protected]

®

Documents

FI-0083 Toyota Land Cruiser 79 Series Tub Body External ROPS Rev B