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

ToyoTa LandCruiSer 79 SerieS Tub body 1HZ - Leaf Sprung
AUS.RHD.1HZ:S65510102S
parTS SuppLied
26
QTY
38
QTY
QTY
24
QTY
QTY
QTY
M12 x 30MM Hex Head
M12 Hardened Flat WasHer
M12 spring WasHer
M12 nyloc nut
M12 x 35MM HalF cap screW
M12 sHakeprooF WasHer
22
QTY
44
QTY
22
QTY
QTY
QTY
QTY
M10 x 30MM Hex Head
M10 nyloc nut
M16 x 90MM Hex Head
M16 nyloc nut
QTY
18
QTY
QTY
QTY
QTY
QTY
M8 x 30MM Hex Head
M8 Flat WasHer
M8 spring WasHer
M8 nyloc nut
M8 serrated Flange nut
M8 x 80MM Hex Head
QTY
32
QTY
16
QTY
16
QTY
QTY
20
QTY
M6 x 20MM Hex Head
M6 Flat WasHer
M6 spring WasHer
M6 x 20MM doMe Head
3.7MM spacer disc (tHrust)
QTY
QTY
QTY
QTY
QTY
QTY
rops cell
rear stay
Front cHassis Bracket
rear cHassis Bracket
rear support Bracket
internal cHassis Bracket
QTY
QTY
QTY
QTY
QTY
L+R
QTY
rear coMpensator plate
spare WHeel Base
reverse Beeper Bracket
HigHligHt guard
4MM rivet
Floor triM teMplate
QTY
QTY
QTY
QTY
QTY
QTY
installers coMpliance plate
saFety cell sticker
saFety cell durolens
150-0190 Bush
150-0190 Crush Tube
M16 x 90MM Hex Head
paCking CHeCk-off
SeriaL number: paCked by: CHeCked by: Page 1 of 26 daTe: daTe:
/ /
/ /
14/10/2011 - Rev B - Fitting Instructions
ToyoTa LandCruiSer 79 SerieS Tub body 1HZ -Leaf Sprung

FI-0083 AUS.RHD.1HZ:S65510102S
ExtERnaL RoLL ovER PRotEction

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

inSTaLLaTion CHeCkLiST
Pre Installation Ensure that the Product Number on the Fitting Instruction document matches that on the products packaging. Verify that the VIN number of the vehicle matches the VIN number on the job card. Ensure that the vehicle airbag configuration is compatible with the ROPS as specified on the manu facturers plate. Refer to Appendix A for illustrations of airbag configurations. Check the functionality of the vehicle electrical system. Check vehicle for Side Curtain Air Bags if the vehicle does, check the ROPS are compatible. If the vehicle is to be road registered advise your signatory for Engineering and Compliance. Notification regarding ROPS installation, Seat belt relocation, Seating capacity reduction etc. Check that all kit contents are present refer to the fitting instructions All paint work and internal trim must be protected to prevent damage during ROPS installation. Ensure that there is no wiring to go under the hood lining before the ROPS is installed i.e. High lights or emergency lighting. Check the location of wiring looms, fuel lines, brake lines, air conditioning lines and ancillary products prior to beginning installation (Check under the floor and under carpet) Do you have all of the required tools for installation inc appropriate eye and hearing protection (PPE)? Post Installation Has the ROPS been installed using the supplied fitting kit? Are all bolts, nuts and tube joiners appropriately tightened? Do all bolts have a minimum of two threads showing through the nut? Have all fasteners been secured to the specified torque settings? Have all tightened bolts had torque paint applied? Ensure that all the star nuts on the load guard are tightened in sequence. Check that wiring looms, brake lines and fuel lines are not crimped, cut or restricted by the ROPS. Check that other ancillary products such as fuel filler release cables work. Check that all rear vehicle lighting is working correctly. Do all seat belts work correctly? (Check no belts are stuck under seats) Have all cover trims, carpets and mats been refitted correctly? Is all padding fitted in the correct position and secured? Are all sharp edges removed from zip ties? Is the load guard/load restraint/load box present and secured appropriately? (Not present on all models refer to kit contents) Are all warning decals and the Safety Cell ID tag applied to the ROPS? Has all local Transport Authority Compliancing been completed including any required seating reduction? Final Inspection This ROPS is installed correctly as per the fitting instructions Test drive the vehicle to ensure that the vehicle is fully functional and that there are no rattles or squeaks present. Log onto the E-Portal http://www.minecorp.com.au/ & complete the E-Trace Record
Page 4 of 26

produCT overview
generaL noTeS
Read through the fitting instructions before attempting to install the ROPS assembly, failing to do so may cause damage to the vehicle or ROPS assembly. It is recommended that the installation be performed by a Licenced Fitter at an accredited Minecorp fitment centre. Designed for use with 2009 model onwards 4.2 Litre 6 Cylinder Diesel (1HZ), Toyota LandCruiser 79 Series Tub Body (Leaf Sprung). Fitment tested on Right Hand drive models only Generic Definitions at end of document Installation Checklist at front of document It is recommended to use a Hand ratchet spanner (not an air ratchet) to avoid stripping critical factory nuts and bolts (e.g. seat belt bolts that have to be removed then refitted into a factory threads)
fiTTing Time
3.5 hours Fitting Instructions - Rev B - 14/10/2011 Page 5 of 26

parTS SuppLied
26
QTY
38
QTY
QTY
24
QTY
QTY
QTY
M12 x 30MM Hex Head
M12 spring WasHer
M12 nyloc nut
M12 x 35MM HalF cap screW
M12 sHakeprooF WasHer
22
QTY
44
QTY
22
QTY
QTY
QTY
QTY
M10 x 30MM Hex Head
M10 nyloc nut
M16 x 90MM Hex Head
M16 nyloc nut
QTY
18
QTY
QTY
QTY
QTY
QTY
M8 x 30MM Hex Head
M8 Flat WasHer
M8 spring WasHer
M8 nyloc nut
M8 x 80MM Hex Head
QTY
32
QTY
16
QTY
16
QTY
QTY
20
QTY
M6 x 20MM Hex Head
M6 Flat WasHer
M6 spring WasHer
M6 x 20MM doMe Head
3.7MM spacer disc (tHrust)
QTY
QTY
QTY
QTY
QTY
QTY
rops cell
rear stay
rear cHassis Bracket
internal cHassis Bracket
QTY
QTY
QTY
QTY
QTY
L+R
QTY
spare WHeel Base
HigHligHt guard
4MM rivet
Floor triM teMplate
QTY
QTY
QTY
QTY
QTY
QTY
saFety cell sticker
150-0190 Bush
150-0190 Crush Tube
M16 x 90MM Hex Head
Page 6 of 26

TooLS required
Metric socket ratcHet set
18MM socket
17MM socket
24MM socket
Hex drive set (Metric)
extension arM set
torque WrencH 5-145nM
Metric spanner set
drill
side cutters
rivet gun
tape Measure
required ConSumabLeS
plastic protective FilM
torque seal paint
veHicle toucH up paint
faSTener ConfiguraTionS
Fastener conFigurations
spring WasHer Hard Flat WasHer Hard Flat WasHer
Flange nut & panel Flange nut & plate Factory tHread Welded nut nutsert nyloc nut
SafeTy noTeS
Remove key from vehicle ignition and detach negative terminal on vehicles battery. Be sure to comply with you workshop safety standards while installing the ROPS assembly. Work safely at all times and proper safety equipment (PPE) must be worn.
Page 7 of 26

STep1.
Remove the Brake fluid line bracket (RH side just forward of the green fuel management system)
STep2.
Remove breather pipe bracket (RH side just forward of the green fuel management system)
STep3.
Remove wiring loom bracket (RH side just forward of the green fuel management system)
Page 8 of 26

STep4.
Remove fuel line bracket (RH side just forward of the green fuel management system)
STep5.
Remove forward RH brake line bracket
STep6.
Remove forward RH wiring loom bracket
Page 9 of 26

STep7.
Remove the forward RH side fuel line bracket
STep8.
Remove forward LH side fuel line bracket
STep9.
Remove the exhaust join bolts under cab
Page 10 of 26

STep10.
Remove front exhaust pipe flexi mount nuts
STep11.
Remove exhaust join at the muffler end
STep12.
Remove rear exhaust pipe flexi mount nuts
Page 11 of 26

STep13.
Carefully lift muffler off rubber mounting bracket and lower the muffler end to the ground. (Leave the most rear rubber mount bolted) Carefully remove forward exhaust tube section
STep14.
Lever the LH side fuel line bracket out from the chassis rail by approximately 6mm
STep15.
Using a hammer tap the chassis spacers into place on the Front Chassis Clamp Brackets (Spacers to face inside)
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.
*Torque Settings Table at end of Document
caution
8x
Page 12 of 26

STep16.
Using a hammer tap the chassis spacers into place on the Inner Chassis Brackets (Spacers to face inside)
8x
STep17.
Remove the floor hatch from the tub and the four 8 mm bolts (1 in front of the hatch and 3 behind the hatch).
STep18.
Note the orientation of the template in relation to the front of the vehicle and the Right hand side and Left hand side of the the vehicle
Align the trim template with the existing holes in the tray and cut the specified area as marked.
L+R
QTY
Floor triM teplate
Page 13 of 26

STep19.
Remove the tub mounting bolt from the front tower post.
STep20.
Place the internal Chassis brackets on the chassis between the vehicle cabin and the first tower mount.
QTY
inner cHassis Bracket
STep21.
Using a trim removal tool, release the accessory clips on the auxiliary power line on the RH side next to the front ROPS chassis clamp location that is running to the fuel management system.
Page 14 of 26

STep22.
Place the Chassis clamping bracket over the chassis ensuring the tower is covered by the bracket. Bolt the bracket to the internal bracket using M12 x 30mm hex head bolts, washers and a Nyloc Nut . The tower holes only have one washer each on the outside.
QTY
STep23.
M12 x 30mm
12x
Insert a 12 x 30m Hex Head Bolt with a Spring washer and a flat washer through the tub mounting hole and bolt into the top of the chassis clamping bracket.
2x
M12 x 30mm
STep24.
Place the Main Hoop Assembly Over the tub and slide it over the Chassis clamp brackets.
QTY
rops cell
Page 15 of 26

STep25.
Align the holes and bolt together using the M12 x 30 mm Hex bolts with one washer on each bolt and a nyloc nut.
12x
M12 x 30mm
STep26.
Using a hammer tap the chassis spacers into place on the Rear Chassis Clamp Brackets (Spacers to face inside)
4x
STep27.
Remove the existing bolts from the tub cross member above the wheels (by the second tower mount.) Fit the Rear Chassis Brackets over the chassis and into the second tower mount. Drill throught the factory threads and the tub cross member using a 10mm bit.
QTY
4x
Drill
Page 16 of 26

STep28.
Fit the Rear Chassis Brackets over the chassis and into the second tower mount. Bolt the upper part of the bracket to the tub cross member (through the drilled holes) using the M8 x 80mm Hex Head Bolts, Spring Washer, Flat Washers and a serrated flange nut.
4x
M8 x 80mm
STep29.
Bolt the Bracket welded to the Main Hoop Assembly into the existing factory thread in the floor of the tub, Use a M8 x 30mm Hex Head bolt, spring washer and flat washer. M8 x 30mm Hex Head
2x
M8 x 30mm
STep30.
Drill holes through the tub using a 12mm drill bit whilst using the bracket as a guide. Deburr the hole from the top and bottom.
4x
Drill
Page 17 of 26

STep31.
Bolt the Bracket welded to the Main Hoop Assembly through the drilled holes, using M10 x 30mm Bolts, Flat washers and a Nyloc nut.
4x
M10 x 30mm
STep32.
Place the rear support bracket into the tub aligning the holes with the existing threads in the tub. Drill out two holes diagonally across each other using a 12mm drill bit.
QTY
14x
Drill
STep33.
Debur the holes top and bottom. Bolt the Rear support bracket through the drilled holes using M10 x 30mm Bolts.
M10 x 30mm
4x
Page 18 of 26

STep34.
Drill the holes through the tub using a 12mm drill bit and the rear support bracket as a guide. Unblot the two bolts from the bracket. Debur all the holes top and bottom.
14x
Drill
STep35.
Bolt down through the Rear Support Bracket and the floor using M10 x 30 Hex Head Bolts and a flat washers and a Nyloc nut. Torque bolts to the specified Torque settings.
14x
M10 x 30mm
STep36.
Bolt through the top holes of the Rear Support Bracket and the wheel arch using M10 x 30 Hex Head Bolts and a flat washer, Rear Compensator Plate, Flat Washer and Nyloc nut. Torque bolts to the specified Torque settings.
QTY
4x
M10 x 30mm
Page 19 of 26

STep37.
Fit the Rear Stays into place by bolting the M16 Bolt, Washers and Nyloc Nut.
QTY
2x
rear stay
M16 x 90mm
STep38.
Fit the coupling bolts (M12 x 35 Half Cap screw) including the Shakeproof Washers. Torque bolts to the specified Torque settings. Apply torque paint to all torqued bolts.
4x
STep39.
M10 x 35mm
Fit the existing Spare wheel bracket on to the ROPS using the remaining M6 hex head bolts, washers and Serrated Flange Nut.
8x
M6 x 20mm
Page 20 of 26

STep40.
Bolt the Protector covers using M6 x 20mm Dome head Bolts, Flat washers, a Springwasher and Serrated Flange Nut.
QTY
8x
HigHligHt guard
M6 x 20mm
STep41.
Place the Spare Wheel base plate over the existing tire supports. Space the plate 150mm from the head board. Drill the holes using an M10 drill bit. HEADBOARD
150mm
4x
Drill
STep42.
Bolt in to place using M8 x 30mm Hex Head bolts, flat washers and a Serrated Flange Nut.
QTY
4x
spare WHeel Base
M8 x 30mm
Page 21 of 26

STep43.
Fill out the Installation Checklist at the front of this document and submit it to Minecorp through your e-portal.
STep44.
Fill out Safety Cell Installation Record triplicate form, store the white page in the Vehicles glove box, keep the yellow form for your records and return the blue copy to Minecorp Head office (PO Box 363, Acacia Ridge, QLD). Manufacturer Warranty VOID if NOT Completed
STep45.
Engrave the supplied compliance plate with the Vehicle and Installer information. Attach the plate to the leg of the ROPS Cell using the supplied rivets.
QTY
3x
4mm
Page 22 of 26

STep46.
Apply the Safety Cell Durolens sticker to the Vehicles rear window.
QTY
reverSe aLarm braCkeT

Note: the reverse alarm bracket fits undernieth the beacon bracket and utilises the same mounting points as the beacon.
QTY
Page 23 of 26

generiC definiTionS
single caB
caB cHassis
dual caB / creW caB
caB cHassis
extra/space/king caB
caB cHassis
LHS - Left Hand Side
van/Mini Bus
Wagon
RHS - Right Hand Side
e-pillar
d-pillar
c-pillar
B-pillar
a-pillar
Torque Paint PPE ROPS Right hand Left hand Bonnet
- Paint used to indicated a bolt or nut is at the desired torque and has not been tampered with. - Personnel Protective Equipment - Roll Over Protection System - Right hand side when looking forward from the rear of vehicle - Left hand side when looking forward from the rear of vehicle - Engine bay hood
Hex Head Nominal Size & Thread Pitch
Bolt Torque Table Nutsert
Half Cap
Button Head
M10 x 1.50 M12 x 1.75 M16 x 1.75 Page 24 of 26
44 Nm / 32 ft lbf 74 Nm / 54 ft lbf 142.2Nm / 105ft lbf
Bolt Torque Specification: Nm / ft lbf 27 Nm / 20 ft lbf 44 Nm / 32 ft lbf 88 Nm / 65 ft lbf
44 Nm / 32 ft lbf
FRONT
BACK
S65510102S
14/10/2011 Phone australia: 1300 922 881 Phone international: +61 1300 922 881
- Issue: 1 Web: minecorp.com.au eMail: sales@minecorp.com.au

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

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

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Copyright:

Available Formats

ToyoTa LandCruiSer 79 SerieS Tub body 1HZ - Leaf Sprung

M12 x 30MM Hex Head

M12 Hardened Flat WasHer

M12 spring WasHer

M12 nyloc nut

M12 x 35MM HalF cap screW

M12 sHakeprooF WasHer

M10 x 30MM Hex Head

M10 Hardened Flat WasHer

M10 nyloc nut

M16 x 90MM Hex Head

M16 Hardened Flat WasHer

M16 nyloc nut

M8 x 30MM Hex Head

M8 serrated Flange nut

M8 x 80MM Hex Head

M6 x 20MM Hex Head

M6 serrated Flange nut

M6 x 20MM doMe Head

3.7MM spacer disc (tHrust)

Front cHassis Bracket

rear cHassis Bracket

rear support Bracket

internal cHassis Bracket

rear coMpensator plate

spare WHeel Base

reverse Beeper Bracket

Floor triM teMplate

installers coMpliance plate

saFety cell sticker

saFety cell durolens

150-0190 Crush Tube

M16 x 90MM Hex Head

14/10/2011 - Rev B - Fitting Instructions

ToyoTa LandCruiSer 79 SerieS Tub body 1HZ -Leaf Sprung

ExtERnaL RoLL ovER PRotEction

ToyoTa LandCruiSer 79 SerieS Tub body 1HZ - Leaf Sprung

14/10/2011 - Rev B - Fitting Instructions

ToyoTa LandCruiSer 79 SerieS Tub body 1HZ -Leaf Sprung

ToyoTa LandCruiSer 79 SerieS Tub body 1HZ - Leaf Sprung

M12 x 30MM Hex Head

M12 Hardened Flat WasHer

M12 spring WasHer

M12 nyloc nut

M12 x 35MM HalF cap screW

M12 sHakeprooF WasHer

M10 x 30MM Hex Head

M10 Hardened Flat WasHer

M10 nyloc nut

M16 x 90MM Hex Head

M16 Hardened Flat WasHer

M16 nyloc nut

M8 x 30MM Hex Head

M8 serrated Flange nut

M8 x 80MM Hex Head

M6 x 20MM Hex Head

M6 serrated Flange nut

M6 x 20MM doMe Head

3.7MM spacer disc (tHrust)

Front cHassis Bracket

rear cHassis Bracket

rear support Bracket

internal cHassis Bracket

rear coMpensator plate