P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story...

57
Ref. No. OMDP0304UD-008 Date: Apr. 15, 2003 Area Application: General Production Effective: Aug. 2003 CONFIDENTIAL P.M.G. Product Marketing Guide DYNA 150/100 As we have already informed you on the Global Web or by the letter from the Overseas Marketing Division, Toyota’s Global Web was permanently closed as of December 31, 2002. Therefore, we will provide our Distributors with Product Marketing Guides (P.M.G.) by other means than the website. Please be advised that the new PMGs will be distributed by the following methods. 1. We are sending all the information currently existing in both paper files and CD-ROMs (Word files) this time only. 2. From now on, we will keep you informed of the revised information with paper files only. For PMGs of new models and revised information on vehicles subject to a full-model change or a minor change, a CD-ROM will be provided together with the paper files. Any unchanged parts will not be included with the information. The following items have been revised. No. Sheet title Contents of revision, etc. I. - 4 Lamps II. - 3 Meters II. - 4 Seats The copy and illustration have been replaced. (Illustrations shown in the sheets other than left are not revised to reflect the change.)

Transcript of P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story...

Page 1: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

Ref. No. OMDP0304UD-008 Date: Apr. 15, 2003 Area Application: General Production Effective: Aug. 2003

CONFIDENTIAL

P.M.G.

Product Marketing Guide DYNA 150/100 As we have already informed you on the Global Web or by the letter from the Overseas Marketing Division, Toyota’s Global Web was permanently closed as of December 31, 2002. Therefore, we will provide our Distributors with Product Marketing Guides (P.M.G.) by other means than the website. Please be advised that the new PMGs will be distributed by the following methods. 1. We are sending all the information currently existing in both paper files and CD-ROMs (Word files)

this time only. 2. From now on, we will keep you informed of the revised information with paper files only. For PMGs

of new models and revised information on vehicles subject to a full-model change or a minor change, a CD-ROM will be provided together with the paper files. Any unchanged parts will not be included with the information.

The following items have been revised.

No. Sheet title Contents of revision, etc.

I. - 4 Lamps

II. - 3 Meters

II. - 4 Seats

The copy and illustration have been replaced. (Illustrations shown in the sheets other than left are not revised to reflect the change.)

Page 2: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

DYNA 150/100 CONTENTS

PRODUCT INFORMATION Development Concept

I. EXTERIOR 1. Exterior Design 2. Windows 3. Wipers 4. Lamps 5. Bumpers 6. Mirrors 7. Door Locks 8. Cargo Deck

II. INTERIOR

1. Interior Design 2. Interior Space 3. Meters 4. Seats 5. Steering 6. SRS Airbags & Seatbelts 7. Air Conditioner 8. Audio System 9. Storage Space

III. POWER TRAIN 1. Engine 2. Transmissions 3. Exhaust Systems 4. Differential 5. Clutch

IV. CHASSIS 1. Suspension 2. Brakes 3. Tires & Wheels 4. Frame

V. BODY STRUCTURE 1. Body Structure 2. N.V.H. 3. Anti-corrosion Steel Sheet 4. Serviceability

VI. SPECIFICATIONS

1. Specifications

Page 3: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since
Page 4: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since
Page 5: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

Development Concept Apr. 15, 2003 DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since its introduction in 1985, continuing improvements in the Dyna 150/100 kept it ahead of the times. Now, a completely new Dyna 150/100 has been created to meet the needs of today's market and, increase its market share as the 21st century begins. In preparing for this full model change of the Dyna150/100, we re-evaluated the truck itself as well as the basic functions that would be required of it by society in the new century. Armed with data from our analyses, we set out to develop a truck that would be easy to use, comfortable, and a pleasure to drive. We are confident the new Dyna 150/100 will lead the commercial vehicle market into the 21st century. DYNA Development Concept Development objective: To create a truck that would be as easy to use as possible. The new Dyna 150/100 development concept: "To achieve top rated ease-of- use and functionality in the class." The development team worked especially hard on the driver's field of view, its minimum turning radius, the cargo deck configuration and size, a flat frame for ease of modification, the front and rear axle capacity (top in the class), and a reduced cargo deck height. With its tough and rugged cargo deck, powerful engine, and wide, comfortable cabin, the new Dyna meets the needs of the 21st century with superior performance and functionality.

1

Page 6: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since
Page 7: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

1. Exterior Design Apr. 15, 2003 The objective of the new Dyna's styling can be expressed in two words: simple and emotional. The stylish yet functional cabin design challenges the conventional truck image. It was also designed for ease of entry and exit. Features: - Pursuing a distinctive design led to a flush surface and a wedge line that wraps

around below the windshield from front to side. - The tops of the front pillars are moved 95 mm (9 degrees) forward and 27 mm (3

degrees) outward compared to the current model. This contributes to ease of entry and exit, to a wider interior comfort, and to maintaining an excellent field of view.

- The fender-less pressed doors offer a flush surface and help increase rigidity. - The flush surface minimizes wind noise and enhances the quality appearance. - The lower part of the door has been extended to hide the step, enhancing the

overall appearance. - The angle of the door opening is enlarged from 60 degrees to 68 degrees for

excellent ease of entry and exit. - The front, side, and center garnish are the same color and the same material,

which standardizes the appearance of the front. - Two colors — White and Blue — are available. In addition, silver metallic is

available for Singapore Just-low models.

1

Page 8: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 9: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2. Windows Apr. 15, 2003 The new cabin design includes larger side windows for an increased field of view and an airy, open feeling inside the cabin. Features: - Compared to the current model, the new Dyna's vertical field of view is 4 degrees

lower to the road and 0.5 degrees higher at the roof for excellent visibility. - The windshield glass is made 50 mm larger vertically for a larger field of view. - In a new method of installing the windshield glass, urethane adhesive is used

between the weather stripping and the panel, which help enhances both waterproof properties and rigidity around the windshield.

1

Page 10: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 11: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

3. Wipers Apr. 15, 2003

Enhanced wiper performance helps ensure a clear view to the front during inclement weather. Features: - All new Dynas have wipers with a mist position that sprays washer fluid on the

windshield and gives it a single swipe to provide a clear view to the front. - The longer 500 mm wiper blades clear a larger windshield area. - Easily refilled washer fluid reservoirs are located under the dashboard — 3.0-liter

capacity in RHDs and 3.8 liters in LHDs. - Wipers have an intermittent speed setting*. - The 1.7-liter washer fluid reservoir located in the pillar on heaterless Dynas. - Fluid level windows in the washer fluid tanks make fluid level checks quick and

easy (not available in Dynas without heaters.) *Please refer to the Order Guide for detailed specifications.

1

Page 12: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

4. Lamps Apr. 15, 2003 The design of the lamps enhances the appearance of the Dyna compared to conventional commercial vehicles. And the headlamps project a strong light pattern that illuminates the road ahead at night or during inclement weather. Features: - The headlamps have halogen bulbs to spread the light pattern wider and farther. - New fog lamps* in the front bumpers offer superior illumination even in foggy

weather. - Large new headlamp module includes headlamp, front and side turn signal,

clearance lamp, and cornering lamp, boosting visual appeal. *Please refer to the Order Guide for detailed specifications.

1

Page 13: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

5. Bumpers Apr. 15, 2003

The front bumper was designed as an extension of the body, with the same color, which challenges the image of conventional commercial vehicles. Nevertheless, these bumpers have all the strength commercial vehicles need. Features: - The color-coordinated bumper was designed to look like part of the body,

enhancing the overall appearance. - The bumper is larger in cross section and shaped for higher rigidity.

1

Page 14: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

6. Mirrors Apr. 15, 2003 The size and location of the door mirrors were refined to maximize the view to the rear. Features: - The outer mirrors measure 236 mm tall by 142mm wide, and offer an excellent

view to the rear. - Under mirrors* on the front and sides give the driver an excellent view of the road

in front and at the sides of the truck. *Please refer to the Order Guide for detailed specifications.

1

Page 15: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 16: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

7. Door Locks Apr. 15, 2003 The door locks offer enhanced functions and quality appearance. Features: - The full case outside handles have the key cylinders built in, which enhances the

overall appearance. - New electronic locks* on the passenger-side doors are more convenient. *Please refer to the Order Guide for detailed specifications.

1

Page 17: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

8. Cargo Deck Apr. 15, 2003 The steel deck was designed for commercial use, with excellent durability and load-carrying capacity. It enhances the Dyna's utility and reliability. Features: - Steel decks to fit the wheelbase of each model are available. - The high deck opens on three sides to make it easier to use. - Minimizing the distance from the frame to the deck lowers the deck height,

making it easier to load and unload. (Just-low models for Singapore only) - The cargo space on the deck of the standard 2300 mm wheelbase model is 2850

mm long, 1600 mm wide, and 380 mm deep - the largest in its class. - The cargo space on the deck of the long 2545 mm wheelbase model is 3110 mm

long, 1600 mm wide, and 380 mm deep - the largest in its class.

1

Page 18: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 19: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since
Page 20: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

1. Interior Design Apr. 15, 2003 To create a bright, easy-to-use space, the functional cabin was designed to be clean and smart looking. QUALITY PURSUED INSIDE - Garnish on the front pillars and lower portion of the quarter pillars enhance the

overall appearance. - The one-piece door trim and headliner enhance the interior feel. - The line that connects the dashboard with the shoulder of the door trim melds the

cabin into a unit, enhancing the overall appearance. PURSUIT OF GREATER OPERABILITY - The dashboard's center cluster centralizes all controls and switches, enhancing

ease of operation. DESIGNED FOR GREATER LEGIBILITY - The dashboard top is lower and slanted forward for excellent forward visibility and

a feeling of openness inside the cab.

1

Page 21: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 22: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2. Interior Space Apr. 15, 2003 The interior was designed with the functions that a truck needs and the comfort drivers and passengers want for long-distance driving. Features: - The cabin is 1530 mm wide, which allows three adults to sit with ample room. - Moving the top of the front pillars forward, among other design changes, helps

give a feeling of excellent headroom. - The cabin's ample legroom offers occupants comfort as well as ease of entry and

exit.

1

Page 23: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

3. Meters Apr. 15, 2003 The meters and warning lamps were designed for legibility. Features: - The meters use backlit illumination, which makes them particularly legible at night. - A large speedometer is located in the center of the meter cluster, flanked by a

tachometer* on the right and temperature and fuel gauges on the left. - The entire cluster was designed for excellent visibility. - The warning lamps are located at the top of the cluster, and laid out for superior

legibility. - New stepper motor moves the instrument needles. - All instruments are illuminated, including dial faces and indicator lamps, with

mercury-less LEDs (Light-emitting Diodes) that help protect the environment, conserve energy, and reduce maintenance requirements.

- Various warning indicators are newly positioned. *Please refer to the Order Guide for detailed specifications. Km/h

1

Page 24: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

Km/h with tachometer

MPH with km/h

2

Page 25: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

4. Seats Apr. 15, 2003 The seats were carefully designed with a new shape and controls that minimize fatigue on long trips. Features: - Considerable attention was paid to seating comfort and support, which resulted in

revised cushion characteristics and shape that minimize fatigue on long trips. - The driver's seat adjusts on a 180 mm slide, and reclines 2 degrees in 36 steps.

Thus, the driver will be able to adjust the seat to his desired position. - In addition to standard fabric upholstery, more durable leatherette* upholstery is

also available. - Stitching pattern on seatbacks and seat cushions is changed. *Please refer to the Order Guide for detailed specifications.

1

Page 26: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 27: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

5. Steering Apr. 15, 2003 The steering mechanism was designed not only for ease of operation but also to help absorb collision impact. POWER STEERING OFFERS QUICK, LIGHT OPERATION. - The hydraulic fluid pressure of the standard power steering is controlled by the

engine rpms. That means light steering at low vehicle speeds and a slightly heavier touch at higher speeds.

ADJUSTABLE STEERING COLUMN (SINGAPORE) - Newly developed tilt & telescope steering column helps drivers of various

physiques find a comfortable steering position. - The column tilts over 8.2 degrees and telescopes up to 35 mm. IMPACT-ABSORBING STEERING COLUMN (SINGAPORE) - The steering column has a new type impact-absorbing structure. In the unlikely

event of a frontal collision, the steering column will move more forward, helping to absorb impact energy.

- The impact-absorbing steering column helps protect the driver from injury from the steering wheel when frontal collisions cause the steering wheel to move toward the driver. If the driver hits the steering wheel, the steering column moves forward, help to absorbing the impact force and contributing to the driver's protection.

1

Page 28: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 29: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

6. SRS Airbags & Seatbelts Apr. 15, 2003 Center passengers have seatbelts in addition to those for the drivers and outside passengers. With the addition of the center seatbelt, the new Dyna is more protective of all occupants. Features: - Drivers and outside passengers have 3-point ELR seatbelts*; center passengers

have 2-point NR seatbelts*. - The seatbelts are easier to operate with the inner belt attached directly to the

seats and new slide buckles. *Please refer to the Order Guide for detailed specifications.

1

Page 30: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 31: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

7. Air Conditioner Apr. 15, 2003 Effective ventilation system keeps the air fresh inside for more comfortable transport operations. Features: - New boost ventilator* brings in fresh air from outside. *Please refer to the Order Guide for detailed specifications.

1

Page 32: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 33: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

8. Audio Systems Apr. 15, 2003 New audio system makes long trips much easier. Features: - Two systems available: one-speaker AM radio* and 2-speaker audio system with

AM/FM radio*. *Please refer to the Order Guide for detailed specifications.

1

Page 34: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

9. Storage Space Apr. 15, 2003 A range of equipment is available to boost convenience and interior storage capacity. The new Dyna is designed to be an easy-to-use commercial vehicle. PURSUIT OF STORAGE CAPACITY - In addition to the glove compartment, a storage box is located at the top of the

dashboard and glove compartment. - Many storage spaces built into the cabin of the new Dyna include a cardholder

(RHD only) and small storage bin near the center cluster, plus an 1 DIN type box with a lid.

- Pockets in the door trims hold route maps and other such things. - Cup holders* at the bottom of the center cluster are standard equipment. *Please refer to the Order Guide for detailed specifications. PURSUIT OF GREATER CONVENIENCE - In addition to the pillar assist grip, side window guards that also work as assist

grips were placed on the door trims to make entry and exit easier. - A ticket holder was added to the back of the driver's side sun visor.

1

Page 35: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 36: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since
Page 37: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

1. Engine Apr. 15, 2003 The new 3.0-liter diesel engine was chosen for both power and fuel efficiency, and it helps protect the environment. Features: - Replacement of the former 2.4-liter and 2.8-liter engines with one 3.0-liter diesel

provides more power and torque from the increased displacement. - Max. power: 66 kW/3600 rpm. Max. torque: 192 Nm/2400 rpm. - This engine offers the low-to-mid-range torque a truck needs, combined with

clean exhaust emissions that help protect the environment.

1

Page 38: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2. Transmissions Apr. 15, 2003 The 5-speed transmission was refined and the gear ratios revised to better suit the new engine. Features: - Two 5-speed transmissions are available, set to suit the engine output. - With a lighter return spring on 1st and 2nd gears, return to neutral from those

gears is much easier and shifting is much more positive.

1

Page 39: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

3. Exhaust Systems Apr. 15, 2003 The exhaust systems are engineered for lower vibration and noise as well as cleaner exhaust emissions. PURSUIT OF LOWER EXHAUST NOISE - The muffler is larger: 18.4 liters capacity compared to the former 16 liters. This

contributed to reduced noise and vibration. - Ball joints optimally positioned on the exhaust pipes help absorb engine vibration

and contribute to lower noise and vibration.

1

Page 40: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

4. Differential Apr. 15, 2003 The drive train, including the differential and drive shaft, has the durability required of a commercial vehicle, and it reduces operational noise as well. Features: - The hypoid gear was re-engineered for a better match, which reduced whine

noise. - The 2-joint drive shaft was changed welding method to help ensure precision

balance.

1

Page 41: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

5. Clutch Apr. 15, 2003 With the 5L engine, the clutch was changed. The new clutch offers the durability required of commercial vehicles as well as quiet operation. Features: - The turnover type clutch pedal gives the driver a positive feeling during operation. - The pedal ratio and stroke of the clutch pedal were reduced, for a better feel

during operation. - A new 9.5-inch clutch was adopted for the new, more powerful engine. - Turnover assist was increased to 2.8 kgf from 2.1 kgf so the clutch pedal requires

less effort to operate.

1

Page 42: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since
Page 43: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

1. Suspension Apr. 15, 2003 The suspension was designed for superior stability and ride comfort, and also with heavier axle capacity for more payload-carrying ability than the current model. FRONT SUSPENSION Achieving superior ride comfort and durability - The leaf-spring suspension's spring rate was refined for superior handling, stability,

and ride comfort. - The front axle capacity was boosted from 1450 kg (GVW 3000 kg, 1600 kg/GVW

3500 kg) to 1800 kg to increase payload capacity.

REAR SUSPENSION Pursuit of superior durability - Zinc-rich primers used in more places on the leaf springs before painting to further

enhance anti-corrosion qualities.

1

Page 44: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2. Brakes Apr. 15, 2003 Renewed and refined brake booster and hydraulic system achieves an excellent feeling when braking and helps achieve stable braking performance. Features: - Disc brakes in front and drum brakes in the rear help achieve superior braking

performance. - Two-line front-rear brake fluid lines help to ensure braking ability even during

emergencies. - The small-diameter long master cylinder and large-diameter brake booster allow

small brake pedal ratio and result in better feeling when braking. - Changing the parking brake from a stick type to a floor lever type makes it easier

to operate. - The brake system is equipped with LSPV (Load-Sensing Proportioning Valves)

that change rear braking characteristics to match the payload. - The LSPV senses the load on the rear axle and controls the amount of brake fluid

going to the rear brakes to achieve the best possible braking performance for the load.

1

Page 45: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

3. Tires & Wheels Apr. 15, 2003 The tires were developed for commercial vehicles, and designed with ride comfort and durability as major objectives. Features: - On the GVW 3000 kg model, the front tires are 6.00 R15-8PR and the rear tires

are 7.00 R15-8PR. (Single rear tire models) - On the 3500 kg model, the front tires are 6.00R15-8PR and the rear tires are

7.00R15-10PR. (Single rear tire models) - 175R14-8PR (GVW 3500 kg) or 185R14-8PR (GVW 3550 kg) tires for the front

and 155R12-8PR rear double tires for the rear are also available. (Just - low model for Singapore)

1

Page 46: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

4. Frame Apr. 15, 2003 The new frame has been refined against vertical bending rigidity. And its divided structure allows the fitting of a variety of cargo decks. In addition, the new structure offers excellent torsional rigidity. PURSUIT OF RIGIDITY - The frame under the cargo deck is U-shaped in cross section. The cross section

is — 160 mm high and 50 mm deep — and more rigid against vertical bending forces.

- The frame cross members under the cargo deck are located near the spring brackets and bound stoppers contribute to rigidity.

- Special side rails for the rigid suspension reinforce where the shock absorbers are attached.

- Reinforcements inside the side rails help ensure ample strength and superior rigidity.

1

Page 47: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 48: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

EXCELLENT VERSATILITY - For the first time in this class, a divided frame is used - one under the cargo deck,

another under the cabin. This allowed the frame beneath the cargo deck to be made flatter, so it can be more easily adapted to different kinds of load-carrying configurations.

- The 800 mm wide frame assembly is more easily adapted to different cargo deck configurations.

- The side rail rivets are located 370 mm from the vehicle centerline to more easily adapt to various cargo decks.

- The cross members do not protrude above the side members, making it easier to fit various cargo deck configurations.

- The low deck height was achieved for ease of loading and unloading by making the gap between the frame and deck narrower than the current model. (Just-low models for Singapore only)

3

Page 49: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since
Page 50: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

1. Body Structure Apr. 15, 2003 The body structure is designed to absorb collision impact to the cabin, which helps protect the occupants. EXCELLENT SAFETY - The cabin structure was designed with CAE (Computer-Aided Engineering) to

help protect occupants from impact. - The front doors have side impact beams to help protect occupants from side-on

collisions.

1

Page 51: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2. N.V.H. Apr. 15, 2003 NVH measures enhance performance in that department. ANTI-REVERBERATION MEASURES - Placing optimally shaped asphalt sheets on the floor in the optimum position and

making them the optimum thickness, help reduce reverberation. - Beaded and strategically placed reinforcements help control vibration, harmonics,

and reverberation from the intake system, engine, drive train, etc. ANTI-NOISE MEASURES - Sealing materials used in pillars and at the cowl sides help prevent the transfer of

vibration and noise. - Cabin mounts were re-examined and refined to help reduce resonance between

cabin, engine, and drive system. - Bulkheads placed in the front cross members and highly rigid front cab mount

help reduce vibration.

1

Page 52: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

3. Anti-corrosion Steel Sheet Apr. 15, 2003 Anti-corrosion measures for the body and frame result in a long-lasting structure. Features: - The frame receives a thick layer of cathodic primer to boost its anti-corrosion

qualities. - Zinc-rich primers used on the leaf springs before painting to enhance anti-

corrosion qualities. - Galvannealed steel in doors and roof increase the cabin's anti-corrosion

properties. - The side outer panels are a single unit with no drip channel, which boosts anti-

corrosion properties. - Plastic fender sides protect against corrosion.

1

Page 53: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

2

Page 54: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

3

Page 55: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

4. Serviceability Apr. 15, 2003 The body structure was designed to make routine maintenance and servicing easier. Features: - The brake fluid reservoir tank is located under the dashboard on the driver's side.

The cover is easily removed and replaced, making checking and refilling much easier.

- The battery is located on the left side of the vehicle behind the cab where removing the battery or cables or refilling the battery water or other servicing is easier.

- The front engine mounts are bolted to the frame, making it easier to remove the engine if necessary.

1

Page 56: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since
Page 57: P.M.G. - toyotatraining.comtoyotatraining.com/FTP/PMG/Dyna150Gen_PMG.pdf · DYNA Development Story Toyota Dyna continually leads its class in the commercial vehicle market. Since

1. SPECIFICATIONS Apr. 15,

2003

1