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
M10Hardened Flat WasHer
QTY
22
M10nyloc nut
QTY
2
M16 x 90MM Hex Head
QTY
4
M16Hardened Flat WasHer
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
M6serrated Flange nut
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
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
ExtERnaL RoLL ovER PRotEction
FittinG inStRUctionS
FI-0083
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 4 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
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
Fitting Instructions - Rev B - 14/10/2011 Page 5 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
• 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
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 6 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
M10Hardened Flat WasHer
QTY
22
M10nyloc nut
QTY
2
M16 x 90MM Hex Head
QTY
4
M16Hardened Flat WasHer
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
M6serrated Flange nut
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
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
Fitting Instructions - Rev B - 14/10/2011 Page 7 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
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
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 8 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
• RemovetheBrakefluidlinebracket(RHsidejustforwardofthegreenfuelmanagementsystem)
• Remove breather pipe bracket (RH side justforwardofthegreenfuelmanagementsystem)
• Remove wiring loom bracket (RH side justforwardofthegreenfuelmanagementsystem)
STep1.
STep2.
STep3.
Fitting Instructions - Rev B - 14/10/2011 Page 9 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
• Removefuellinebracket(RHsidejustforwardofthegreenfuelmanagementsystem)
• RemoveforwardRHbrakelinebracket
• RemoveforwardRHwiringloombracket
STep4.
STep5.
STep6.
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 10 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
• RemovetheforwardRHsidefuellinebracket
• RemoveforwardLHsidefuellinebracket
• Removetheexhaustjoinboltsundercab
STep7.
STep8.
STep9.
Fitting Instructions - Rev B - 14/10/2011 Page 11 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
• Removefrontexhaustpipefleximountnuts
Removeexhaustjoinatthemufflerend
Removerearexhaustpipefleximountnuts
STep10.
STep11.
STep12.
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 12 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
• 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.
Fitting Instructions - Rev B - 14/10/2011 Page 13 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
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
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 14 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
• 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
Fitting Instructions - Rev B - 14/10/2011 Page 15 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
• Place the Chassis clamping bracket over the chassis ensuringthetoweriscoveredbythebracket.
• BoltthebrackettotheinternalbracketusingM12x30mmhexheadbolts,washersandaNylocNut.
• Thetowerholesonlyhaveonewashereachontheoutside.
12xM12 x 30mm
STep22.
STep23.
STep24.
QTY
2
Front cHassis Bracket
• 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
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 16 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
• 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
M8serrated Flange nut
Fitting Instructions - Rev B - 14/10/2011 Page 17 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
• 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.
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 18 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
• 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
rear support Bracket
STep33.
• Bolt the Bracket welded to the Main HoopAssemblythroughthedrilledholes,usingM10x30mmBolts,FlatwashersandaNylocnut.
4x
M10 x 30mm
Fitting Instructions - Rev B - 14/10/2011 Page 19 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
• 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
rear coMpensator plate
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 20 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
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
Fitting Instructions - Rev B - 14/10/2011 Page 21 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
• 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
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 22 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
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
installer’s coMpliance plate
• Fill out the Installation Checklist at the front of this document and submit it to Minecorp through youre-portal.
Fitting Instructions - Rev B - 14/10/2011 Page 23 of 26
ToyoTa LandCruiSer 79 SerieS Tub body
1HZ -Leaf Sprung®
AUS.RHD.1HZ:S65510102S
• Apply the Safety Cell Durolens sticker to theVehicle’srearwindow.
STep46.
reverSe aLarm braCkeT
QTY
1
saFety cell durolens
• Note:thereversealarmbracketfitsundernieththebeacon bracket and utilises the same mounting points as the beacon.
QTY
1
reverse Beeper Bracket
AUS.RHD.1HZ:S65510102S
14/10/2011 - Rev B - Fitting InstructionsPage 24 of 26
1HZ - Leaf Sprung ®
ToyoTa LandCruiSer 79 SerieS Tub body
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]
®