ToyoTa 200H o t - F o r m e d A r m o u r e d L A n d C r u i s e r s t A t i o n w A g o n

ToyoTa 200 Hot-Formed Armour

Cutting-Edge armour Technology

The Hot-Forming technology that Jankel has pioneered in the market place fundamentally changes the protection, delivery and price proposition to the customer when compared to conventional armouring methods. Conventional armouring comprises hundreds of pieces of small, flat armour. Hot-Forming replaces these with a 36-piece steel armour system which utilises large pressed panels that are shaped to fit into the vehicle.

This technology delivers measurable protection, weight, cost and delivery time benefits to the customer.

Hot-Formed Armour is used in-house by luxury car manufacturers due to its high-tolerance manufacturing properties. For this reason Jankel have now taken these advanced technologies further for our NGO, VIP, government and defence customer base.

Hot-Formed armour allows Jankel to improve greatly upon conventional armouring methods which are more time consuming, expensive and cannot offer the same consistent and certified level of protection from vehicle to vehicle.

We have applied Hot-Formed armouring techniques to the Toyota 200 Series Land Cruiser to offer a highly protected, live-fire certified vehicle which can be rapidly manufactured at a highly competitive market price.

This technology is not available from any other manufacturer of armoured Toyota 200 Series.

ToyoTa 200

Benefits to the Customer

Conventional armouring methods date back to over 100 years ago and are still the industry benchmark. The innovative new hot-forming solution from Jankel makes a giant leap forward to offer the customer the following benefits to improve over that of the conventional approach:

• Lighter, faster to produce and lower in cost. Hot-forming reduces the armour component count in the vehicle down to 36 parts, resulting in simplified one-piece structures and a significant reduction in welding and bolting of components.

• The highest levels of blast certification. Use of large one-piece components from the firewall to the rear cargo area offer an incredibly strong structure to protect against blasts; this is particularly important for front wheel and side-blast threats.

• Higher levels of blast protection without compromising the ballistic protection in any way. Hot-forming uses an armour material called BSEC510. Unlike conventional ballistic steel, BSEC510 has properties which optimise hardness and tensile strength allowing it to defeat higher levels of blast without cracking, as well as the traditional ballistic threats.

• Guaranteed repeatability and consistency in manufacture. The formed components

are manufactured using OEM tolerances. All panels are identical with a tolerance of ± 0.5mm. For the first time in the industry, the production vehicle is guaranteed to be identical to the tested vehicle.

Armour sYstem

ToyoTa 200 CertiFiCAtion oF ProteCtion

There are many material standards used in the industry by both customers and suppliers which relate to the performance of materials in a laboratory. There is only one standard which tests the actual vehicle. This is the benchmark for the industry which the customer can trust; this is the German VPAM standard and is witnessed by and signed off by Government officials. The Jankel Toyota 200 is certified to this level.

Ballistic CertificationVPAM BRV 2009 Level VR7

• 5.56 x 45 mm (MEN, SS109) FMJ, PB, SCP [220 rounds fired]

• 7.62 x 51 mm (MEN, M80) FMJ, FB, SC [192 rounds fired]

Blast CertificationVPaM ERV 2010

• 15 kg tnt detonated 2 m from side of vehicle (note: highest level within the standard)

• 2 x dm51 hand grenades detonated simultaneously on the roof

• 1 x dm31 hand grenade detonated under the driver seat

AEP-55 Hybrid-3 TestingTesting was also undertaken using a Hybrid-3 dummy to record all the forces sustained by the occupant during the following blast events. Please note that 15 kg TNT at 2 meters produces the same blast pressure as 120 kg at 4 meters. Certificates and reports are available upon request.

stAnAg 4569 Level 1 - DM31 anti-personnel mine detonated under driver’s seat

stAnAg 4569 Level 2a - 6 kg TNT detonated under the front wheel

erV 2010 - 15 kg TNT detonated 2 meters from the side of the vehicle

ToyoTa 200

Jankel has developed a number of enhanced protection features into the vehicle which support our new Hot-Formed Armour system.

Material IntegrationThe 36 pieces of steel armour are installed into the vehicle and overlap where they meet creating a strong and robust integrated monocoque. This further reduces welding, bolting, welding-support armour and labour required for installation.

Overlaps & Spall ReturnsHot-Forming enables Jankel to press the overlap and spall return in one piece as part of the main side panel. This spall return profile aligns with the armour in the door perfectly every time due to OEM tolerances of the pressed part.

Front Screen Retention SystemThe front screen is anchored to the internal A-pillar. This prevents it from being sucked out or pushed into the vehicle in very large side blasts.

Door DesignA frame is fabricated inside the Toyota door skin to enable it to carry the whole weight of the steel armour and framed glass ensuring longevity.

Glass ProfileAll side door glass is of a block design and does not use a larger outer laminate. This design assists in side blast protection and general levels of glass durability.

Door Glass Engagement FramesThe door glazings are held within purpose built frames which firmly hold the glass in place during a side blast event to prevent the glass being sucked into or blown out of the vehicle.

Armour sYstem engineering

ToyoTa 200 sYstems integrAtion

Each customer has individual requirements on their vehicles to meet their specification. Jankel brings almost a decade of manufacturing and integration experience to the customer, having produced over 1000 armoured Toyota vehicles to date. Systems we have installed into customers’ vehicles include the following:

• Electronic Countermeasures Systems (Signal Jammers)

• Codan & Barrett HF radios

• Motorola VHF radios

• Satellite phones

• Vehicle trackers

• Incident data recorders

• Covert camera systems

• Infra-red lighting systems

• Complete vehicle blackout systems

• Customer supplied surveillance and eavesdropping equipment

• Roof hatches

• Modified seating systems Jankel can fit customer supplied equipment or can supply the equipment to the customer specification.

All vehicles are prepared for communications installation; such systems can be installed by the customer once the vehicles have arrived, should it be desired.

ToyoTa 200

Automotive certification has equal importance to armour certification as the completed vehicle will be subjected to a demanding duty cycle in hazardous conditions. The vehicle must perform safely and reliably on a daily basis and not add to the risks of mission failure or dangers to the user. It is with this in mind that Jankel has gone further than any other manufacturer in eradicating risk to those who use our product. We have achieved this through working with experts in product development and validation throughout the design process. Braking: High performance Alcon replacement braking system fitted front and rear, testing and rated to a GVW of 5500 kg.

Suspension System: Bilstein suspension system with heavy duty springs and dual reservoir dampers, steering damper and roll bars, tested and rated to a GVW of 5500 kg. Wheels: Heavy duty Toyota wheels which are subjected to cornering, radial fatigue tests and impact tests in accordance with SAE standards at 5800 kg GVW. Tyres: The selected tyre has a speed rating of 170 kph and weight rating of 1450 kg to provide a maximum GVW of 5800 kg. Complete Vehicle Certification: The vehicle has also gained certification against the requirements of the European Individual Vehicle Approval (IVA) Manual for M1 Passenger cars to prove compliance to UK & EU National roadworthiness requirements.

ComPLete VeHiCLe engineering

ToyoTa 200

Support

The Jankel Through Life Support Team have developed a range of comprehensive support packages on the Hot-Formed Armoured Toyota Land Cruiser 200 Series which go further than any other armourer in the support of customers in the most hostile environments. Effective support of armoured vehicles will extend service life, reduce maintenance costs, reduce accidents and increase vehicle availability.

Our Field Support Team is regularly supporting humanitarian and diplomatic customers worldwide, including hostile environments such as Libya, Haiti, Lebanon, Afghanistan, Iraq and Somalia.

Aspects of the support currently being delivered to customers include:

• Comprehensive publications library that includes Operator Handbooks, Illustrated

Spare Parts Catalogues, RenderSafe Instructions and Workshop Manuals.

• Operator / maintainer familiarisation training.

• Service & Maintenance plans, covering the first two years of use, to include four service visits per year with all parts included.

• Management and administration of the vehicle warranty.

• Supply and delivery of Toyota and Jankel spare parts.

• Technical advice helpline to advise on all aspects of fleet support.

• Ad hoc service visits upon request.

tHrougH LiFe suPPort

ToyoTa 200 ProduCtion

The Hot-Formed armour technology delivers significant production benefits to Jankel which are subsequently presented to the customer through lower prices and faster production times. The key production aspects of the project are as follows:

OEM Toleranced Hot Formed ComponentsThe hot formed panels are pressed and profiled with minimal tolerances to ensure they fit first time, every time. This saves significant amounts of labour at armour installation stage which is reduced to 20 hours per vehicle, an 80% reduction over conventional armouring methods.

This significant decrease in labour content is the largest single contributor to the fast delivery and lower prices we offer to the customer. Vacuum formed trim components and manufactured looms further reduce production time and increase conformity of production. Large Purpose Built Production FacilitiesOur large production facilities in South Carolina and Jordan are purpose built for armoured vehicle manufacture enabling us to scale up production to meet the most urgent customer requirements. Stock Build Programme Offering the shortest delivery times to customers means building complete armoured vehicles for stock. Our stock program has a minimum of 40 vehicles in the production system at various stages of completion which can be adopted by a customer. These vehicles are built to a mid-level specification and can still be altered to meet the customer required specifications.

ToyoTa 200

The Hot-Formed armour system was developed for integration into any LC 200 model, the key specifications of which are as follows.

Common Land Cruiser 200 Specifications

• 4.5 L V8 Twin-Turbo-Charged Diesel Engine Standard 136 kW (182 hp) @ 3200 rpm; 430 Nm (454 lb-ft) @ 1200-3600 rpm

Intercooled 162 kW (217 hp) @ 3600 rpm; 430 Nm (454 lb-ft) @ 1200-3600 rpm

• 4.0 L V6 VVT-i Petrol Engine 179 kW (240 hp) @ 5200 rpm; 376 Nm (277 lb-ft) @ 3800 rpm

• 4.6 L V8 Petrol Engine 234 kW (314 hp) @ 5600 rpm; 460 Nm (339 lb-ft) @ 3400 rpm

• Hi-lo part-time 4WD and rear limited slip differential

• 93 Litre fuel tank + 45 Litre reserve tank

• Manual or automatic gearbox

• Swing-out barn or lift-up clamshell rear doors

• Variety of trim and equipment levels available

Security Upgrades

• Door deadbolts

• 50 km Hutchinson runflat system

• Siren, PA and Intercom system

Dimensions

Weights

Driving

Length 4950 mm

GVW 5025 kg

Fuel Cap. 138 litres

Width 1970 mm

Unladen 4200 kg

Range 750 km

Height 1880 mm

Payload 825 kg

AutomotiVe sPeCiFiCAtion

• Dual battery system• Recovery equipment, tool kit and First Aid kit

Upgraded Vehicle Dimensions and Weights

JANKEL ARMOURING LIMITED

PO Box 1, Weybridge, Surrey,KT13 8XR, United Kingdom

T +44 (0) 1932 857766F +44 (0) 1932 855694

E info@jankel.comW www.jankel.com

© The Jankel Group 2013

Armoured Toyota 200 Land Cruiser mar 2013 v2.7

Jankel believes the content of this brochure to be correct at the time of printing, but makes no warranty as to this.

Jankel continuously strive to maintain their technology to cutting-edge, market-leading standards and therefore reserves the right to alter specifications at any time, without notice.