UD Trucks MKB35A MKB37A PKC37A Body Installation Manual 2009 – Chassis Body Builder Guide PDF

Description

The UD Trucks MKB35A MKB37A PKC37A Body Installation Manual 2009 is the document issued by UD Trucks to guide body manufacturers, second-stage-of-manufacture (SSM) builders, and modification companies through the correct installation of rear bodies and ancillary equipment onto the MKB35A, MKB37A and PKC37A forward control 4×2 medium-duty truck chassis-cab. Issued 15 May 2009, it sets out the basic data and precautions required to design and manufacture a quality body that satisfies the customer’s requirements while keeping the completed vehicle compliant with all applicable Australian Design Rules (ADRs).

File Details

• Manual type: Body Installation Manual
• Brand: UD Trucks (Nissan Diesel Motor Co., Ltd. Japan)
• Models covered: MKB35A, MKB37A, PKC37A
• Language: English
• Page count: 152
• File format: PDF
• Issued date: 15 May 2009

Chapters Covered

• General Overview and Australian Design Rules (ADR) Certification
• Vehicle Manufacturer, Second-Stage-of-Manufacture and Manufacturer’s Guidelines
• Australian Vehicle Standards Rules 1999, Load Restraint Guide and Concessional Mass Limits
• ADR Summary and SSM / Body Builders ADR Checklist
• Sub-Frame and Body Installation — shape, front-end design, reinforcement positions, mounting brackets, location plates
• Combination with Chassis Frame — U-bolt mounting, fore-and-aft movement prevention, sub-frame connecting devices
• Long Wheelbase Truck Guidelines
• Chassis Frame — drilling and riveting
• Mechanical Connections Between Vehicles — towbars, tow couplings, fifth wheels
• Lifting Devices — cranes and tailgate/platform loaders
• Precautions During Electric Welding
• Precautions on Vehicles Equipped with ABS and EHS
• Relocation of the High Output Fuse Box
• Remodeling the Exhaust System
• Allison Automatic Transmission Precautions and Optional Features
• Tightening Torque of General Chassis Bolts
• Chassis Layouts for MKB35AD-R, MKB35AG-R, MKB35AL-R, MKB37AE-R, MKB37AF-R, MKB37AK-R, MKB37AL-R, PKC37AH-N, PKC37AK-N, PKC37AN-N, PKC37AR-N, PKC37AS and air suspension variants
• Frame Assembly and Section Modulus
• Allowance for Rear Axle, Suspension and Tyre Articulation
• Engine PTO and Transmission PTO
• PTO Circuit — manual and automatic transmission models
• Engine Control System with Electronic Governor
• Electrical System — harness for rear lamps, fuse box, relay and additional power sources
• General Precautions on Electrical Wiring
• Wiring Diagrams and How to Read Them
• Air System — discharge, preferential charging, nylon tube installation and removal
• Air Piping Diagrams
• Painting Precautions and Allowable Temperature Limits

Across its 152 pages, the UD Trucks MKB35A MKB37A PKC37A Body Installation Manual 2009 gives a body builder everything required to plan and execute an installation correctly. It opens with a full ADR certification framework so the SSM understands exactly which compliance responsibilities belong to them and which remain with the first-stage manufacturer. From there it works through the physical build: the required shape and mounting of the sub-frame, the correct way to drill and rivet the chassis frame without causing stress concentration, and the special precautions that apply when welding near ABS, EHS or Allison transmission components. The middle of the manual is packed with dimensional drawings: complete chassis layouts for every wheelbase and suspension combination, frame assembly drawings, section modulus data, and the clearances that must be left for rear axle, suspension and tyre articulation. It then moves into the systems a body builder must interface with — engine PTO and transmission PTO specifications including output torque, drive ratio, rotation direction and drive flange data; the PTO circuit diagrams for manual and Allison automatic models; the engine control system with electronic governor; the electrical system with rear lamp harness wiring, fuse and relay locations, and additional power source terminals; and the air system including the preferential charging requirements of ADR 35/02. Wiring diagrams and air piping diagrams are included for reference, and the manual closes with painting precautions and allowable temperature limits for major parts.

What This Body Installation Manual Enables

The value of this manual is not generic truck knowledge — it is the exact dimensional and compliance data a body builder needs before a single hole is drilled. With it in hand, a fabricator can size and shape a sub-frame that will not crack the chassis rail, choose correct mounting brackets and location plates instead of relying on friction U-bolts, work out the exact front-end reinforcement position, and confirm the PTO output and wiring circuit for the specific model on the hoist. It answers the questions that decide whether a completed truck passes inspection: where can I weld, where can I drill, how close can the body get to the air suspension, how much rear overhang deflection must I allow for, and which lamps and reflectors must be added at second-stage-of-manufacture.

Why the UD Trucks MKB35A MKB37A PKC37A Manual Matters

Chassis frames on these trucks are a riveted and bolted construction, often high-tensile steel that is easily weakened by careless heat or stress concentration. The manual is explicit about the consequences: distorted flanges, cracked gussets, loosened U-bolts, and load paths that change suddenly where rigidity steps up. It documents the correct procedures for electric welding near electronic control units, the mandated disconnection sequence for batteries and ECUs, and the ABS/EHS precautions that must be respected when installing body equipment within 100mm of sensors and harnesses. The ADR checklist shows exactly which lamps, reflectors, marker plates and registration plate mounts become the body builder’s responsibility once the chassis leaves the UD Trucks line. For anyone building, modifying or certifying a vehicle on the MKB35A, MKB37A or PKC37A platform, those details are what separate a compliant finished truck from one that fails inspection.

Document Delivery and Use

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This 2009 UD Trucks body installation guide is supplied as a digital PDF that downloads immediately after payment. There is no shipping and no waiting for a physical book. The file opens on any device — desktop, laptop, tablet or phone — and every page is printable, so the relevant chassis layout, wiring diagram or PTO specification can be taken straight to the workshop floor and used as a working reference while the body is being built.