NT400 Bodybuilder Manual V4-1

Edition 4, May- 2016 NTCE – LCV Engineering
ENGINEERING BODYBUILDER STANDARDS

FOR BODY ASSEMBLY, EQUIPMENT AND
CONVERSIONS
Edition: 4, May- 2016
F91A MY13
NTCE – LCV ENGINEERING
1. INTRODUCTION 1 of 15 F91A MY13


CONTROL CHANGE
Edition Chapter Page Description Date of revision
4 2.1.11 9 Chapter "Vehicle delivery" is updated May- 2016
3.2.3 8 Update hours in salt spray chamber
3.2.6 11 Bolt quality and tightening torques table is updated
3.4.1 18 Remark and drawing about rear overhang lengthening are added
3.8.1 24 and 25 Engine control chapter is modified
3.15.2 44 Update note about batteries maintenance
3.15.7 48 Added warnings for new Tachograph of February 2006
3.15.8 49 Table about battery charge status is changed
3.15.9 55 F91G03 connector: Table is modified, comments about PIN6
3.15.9 55 Added note about RPM's signal activation
3.15.9 56 F91G04 connector: Note is updated
4.2.6 10 and 11 Tables of drawings of fixations are updated
5.3.1 8 Remark about minumum clearance to the ground is added
5.3.4 10 Chapter updated
7.1.2 6 Chapter and electrical diagram are updated
7.1.3 7 and 8 Chapter and electrical diagram are updated
7.1.10 17 New chapter


1. INTRODUCTION


INDEX
CONTROL CHANGE ...................................................................................................................................3
1. INTRODUCTION ......................................................................................................................................5
1.1 INTRODUCCION ....................................................................................................................................9
1.1.1 Objective..............................................................................................................................................9
1.1.2 Precautions and warnings ......................................................................................................................9
1.1.3 Classification.........................................................................................................................................9
1.2 DELIVERY RANGE ............................................................................................................................ 10
1.2.1 Composition of versions ....................................................................................................................... 10
1.3. IDENTIFICACION OF MODELS ..................................................................................................... 12
1.3.1 Identification plates .............................................................................................................................. 12
1.3.2 Frame number .................................................................................................................................... 13
1.4. INFORMATION FOR BODYBUILDERS ........................................................................................ 14
1.5. TECHNICAL SUPPORT AND BODYBUILDERS INFORMATION ........................................... 15


1.1 INTRODUCCION
1.1.1 Objective
The present body builder guidelines provide body builders and equipment fitters with important technical information
which must be complied with when designing and mounting bodies for NT400 / CABSTAR range vehicles
manufactured in Europe. For further information about models of other ranges or different origin, please contact the
relevant Customer Service departments or the NISSAN Global Portal in Internet, see chapters 1.4 and 1.5.
Considering the vast number of body types and body builders, the present guidelines cannot predict all possib le
changes and body types and handling characteristics which can occur due to the body activities. Therefore,
NISSAN does not assume any liability for any accidents or breakdowns resulting from the modifications of this kind
made to its vehicles. As a result, NISSAN only accepts liability for its own design, production and present
guidelines.
These body builder guidelines are intended for professional body builders or fitters. Note that some work is only
allowed to be undertaken by appropriately qualified personnel in order to avoid risks of injury and to achieve the
quality needed in the body activities.
The body builder and equipment fitters must strictly adhere to all the present Guidelines when performing any
modifications to the vehicle in order to ensure the good vehicle’s reliability and operation and to meet the warranty
requirements. Otherwise, NISSAN will not be held responsible for the consequences.
On the other hand, any modification carried out on the vehicle must comply with country-specific laws, directives
and approval regulations concerning bodywork and conversion projects.
1.1.2 Precautions and warnings

The use of parts, components and/or not homologated accessories could have adverse effects on the vehicle’s
safety and reliability, therefore, whenever it is compatible with the planned design, it is recommended to use original
NISSAN parts and accessories.
The Standards and Instructions included in the present Body Builder Guidelines correspond to current technical
specifications by the time of their elaboration. Keeping in mind the constant introduction of improvements
implemented by NISSAN in the production of the different vehicle components, such Guidelines and Instructions
can be modified, it is therefore important to check that these Guidelines in the current version are available (see
chapter 1.4).
Before starting the conversion works or body fitting it is essential to carefully read the contents of the present Body
Builder Guidelines.
1.1.3 Classification
In order to make it easier to search for information, this Bodybuilder Manual has been divided into seven sections:
1. Introduction
2. General recommendations.
3. Vehicle modifications.
4. Bodyworks and fitting of equipments.
5. Power Take Off.
6. Technical data, weights and dimensions.
7. Electric wiring diagrams.

1.2 DELIVERY RANGE

1.2.1 Composition of versions
The NISSAN NT400 / CABSTAR de 2,8 a 4,5 tons have been specially designed for the distribution and prepared
for the assembly of multiple bodyworks and fittings in order to meet the market needs.
The range has:

o Tilted and fixed cabs of 3 seats and crew cabs of 6 seats.
o Chassis with three wheelbases and with hydraulic assisted brakes
o Rear axles with single 15” wheels or twin wheels of 15” or 16”.
o Euro5b OBD+ engines with three power levels.
o Euro4 engines destined for countries outside the EU.
o 5 and 6 speed manual transmission gearboxes:
Gross Vehicle Weight (Kg) Engine type (Hp)

Model WB (mm)
[Emissions level]
Transmission
Total FR Axle RR Axle
2500
28.12 2800 1650 1650
2900
LHD 2500
Single cab Rear single 32.12 2900 3200 1650 1900 YD25k3 Lo (121) Manual,
EU markets
(3 seats) wheel 15" 3400 [Euro5b] 5 speed
2500
RHD 34.12 2900 3400 1750 1900
3400
2500
YD25k3 Lo (121) Manual, 5
35.12 2900
[Euro5b] speed
3400
2500
Rear twin YD25k3 Mo (136)
35.14 2900
wheel 15" [Euro5b]
3400
2500
YD25k3 Ho (145)
35.15 2900 3500 1750 2200
[Euro5b]
3400
2500
LHD YD25k3 Mo (136)
EU markets 35HD.14 2900
RHD [Euro5b]
3400
2500
YD25k3 Ho (145)
35HD.15 2900
[Euro5b]
Single cab 3400 Manual,
(3 seats) 2500 6 speed
YD25k3 Mo (136)
45.14 2900
[Euro5b]
3400
4500 1750 3200
2500
Rear twin YD25k3 Ho (145)
45.15 2900
wheel 16" [Euro5b]
3400
2500
35.13 2900 3500 1750 2200
Out EU 3400 YD25k2 Mo (130)
markets 2500 [Euro4]
LHD 45.13 2900 4500 1750 3200
3400
2500
Russia & ZD30H AWP (150) Manual,
35.15 2900 3500 1750 2200
Ukraine [Euro4] 5 speed
3400
2900 YD25k3 Mo (136)
35.14
Rear twin 3400 [Euro5b]
wheel 15" 2900 YD25k3 Ho (145)
35.15
3400 [Euro5b]
3500 1750 2200
2900 YD25k3 Mo (136)
35HD.14
3400 [Euro5b]
EU markets LHD/RHD
2900 YD25k3 Ho (145)
35HD.15
3400 [Euro5b] Manual,
Crew cab 2900 YD25k3 Mo (136) 6 speed
45.14
(6 seats) 3400 [Euro5b]
4500 1750 3200
Rear twin 2900 YD25k3 Ho (145)
45.15
wheel 16" 3400 [Euro5b]
2900
35.13 3500 1750 2200
Out EU 3400 YD25k2 Mo (130)
markets 2900 [Euro4]
LHD 45.13 4500 1750 3200
3400
Russia & 2900 ZD30H AWP (150) Manual,
35.15 3500 1750 2200
Ukraine 3400 [Euro4] 5 speed

The main features of the NT400 / CABSTAR range vehicles are:

o Compact vehicles because of the design of the cab in advanced COE disposition.
o Cabs equipped with different fittings to meet the customer needs.
o Frames that have been designed to fulfill severe use requirements.
o Pre-fittings to make the body activities easier and to satisfy the different needs.
Such pre-fittings can be very useful in certain body conversions, such as:
o Bodybuilders equipment:
 Rear body supports in frame.
 Interfaces for bodybuilders.
 Rear cross member reinforcement (optional).
o Reinforced rear suspension (only for vehicles with twin rear wheels).
o Rear view mirrors with short arms (for bodywork width lower than 2030 mm).
o Batteries high-capacity.
o Ball type towing attachment:
 Fixing bar tow..
 Tow hook.
 Rear cross member reinforcement.
 Electrical system for trailer.
 Trailer socket.
o Power Take Off equipment:
 Power Take Off
 Control lever.

1.3. IDENTIFICACION OF MODELS

1.3.1 Identification plates
In these range models, the Unit Identification Plate (A) is fixed to the surface of the “B” pilar, to the door frame of the
driver side.
The data indicated in the plate are essential to any application of information, documentation or order, the
information included is the following:
In the event of damage or destruction of the plate, it will be substituted on request to the relevant NISSAN
department, see chapter 1.5.
The “Vehicle Type" reference (7) which has been created for a better commercial identification, describes the
vehicle type, its technical equipment and the finish degree. The VIN Model Code covers the digits 8, 9 and 10:
These two data are essential to identificate the vehicle, and will therefore be included in any request for technical
information regarding body activities and conversions.

1.3.2 Frame number

The frame number includes the VIN Model Code which allows the quick identification of the range where the vehic le
belongs. This range is identified with code F24.
This code is part of the vehicle identification number (VIN Code) and corresponds with the digits 7, 8 and 9:
Mexico VIN Model Code:
The frame number is located on the right side member, in the rear axle area (in driving direction), see image.
Both the total and partial concealment of the frame number by any added component are not permitted.

1.4. INFORMATION FOR BODYBUILDERS

In order to determine the best option to choose the vehicle to be converted or transformed, it is essential that the
involved parts (NISSAN, the bodybuilder and the final customer) contribute their experience and knowledge.
The choice of the vehicle must be determined by a good knowledge of the vehicle, and therefore it is n ecessary to
be familiar with the following:
o The technical data, see chapter 6.1.
o Vehicle specifications (such as weights, dimensions, etc.) see chapters 6.2 and 6.3.
o NISSAN drawings for bodybuilders.
o Asssembly procedures and standards.
o Specific type approval data for the 2nd stage COC document or later.
The chapter 6 of the present standards contains information with regard to the technical specifications as well as
the weights and dimensions of the NT400 / CABSTAR range trucks. Nevertheless, wit h the aim of providing a more
efficient and fluid information on the characteristics and modifications implemented to our vehicles, the following
information can be downloaded on the website www.nissan-conversion.com:
o Bodybuilder rules.
o Bodybuilder diagrams (diagrams in CAD in DXF and PDF formats).
o Data for 2nd stage type approval.
On NISSAN’s B2B portal under “Parts and Service” there is the N-WORD section where you can download the
service manuals for all NISSAN brand models.
The B2B portal is available on the website https://eu.nissan.biz.
The service manuals include complete basic information about:
o Installing and removing vehicle systems and components.
o Torques.
o Descriptions of operation.
o Wiring diagrams.
o Maintenance data.
o Etc.
Permission to access this information can be obtained directly on the corresponding websites .

1.5. TECHNICAL SUPPORT AND BODYBUILDERS INFORMATION

Any doubt or suggestion concerning the vehicle modifications, application of bodies, assembly of equipment, or
documentation applications and validations (see chapter 2.1.2), must be presented to the NISSAN departments
created to give support to the Body Builders.
See enclosed chart:
Company Bodybulder's support Telf Telf

The Rivers Office Park, Denham Way
Paul Allen
Nissan Motor (GB) Ltd. United Kingdom WD3 2YS Maple Cross +44*(0)*1923899999 +44(0) 1923 899 845
paul.allen@nissan.co.uk
Hertfordshire
General Almirante, 2
España 34 (0)93 290 7486
08014 Barcelona Aina Peris
Nissan Iberia, s.a. +34 93 290 8344
Lagoas Park, Edifício 4 aperis@nissan.es
Portugal +351 21 836 10 00
2740-267 Porto Salvo
Via Tiberina km. 15,740 +39 (0)690 8081 Marco Mannocchi
Nissan Italia S.p.A. Italia (+39) 06 90808 416
00060 Capena (Roma) m.mannocchi@nissan.it
France Parc de Pissaloup
+33 (0)1 30 69 25 00
13 avenue Jean d'Alembert. Trappes
Hornweg 32
+31 20 516 2222
1044 AN Amsterdam Claude Muller
Nissan Western S.A. Netherlands 0033130692576
Boeingavenue 275 claude.muller@nissan.fr
+31 (0)20 354 9555
1119 PD Schiphol-Rijk
Belgique / België
Renault Nissan Strasse 6-10
+49 2232 57-0
50321 Brühl
Deutschland
Cap-Spich-Strasse 8,
Nissan Center Europe 53842 Troisdorf Hartmut Majewski
+49 2232 57 2011
GmbH Bergermoosstrasse 4  harmut.majewski@nissan.de
Switzerland +41 44 73 65 511
8902 Urdorf
Laaer Ber- Str. 66
Austria 43 1/90577
1100 Wien
Infopark sétány 3/B
Hungary +36 1 371 53 00
1117 Budapest
Aleje Jerozolimskie 176
Poland +48 22 34 51 040
Nissan Sales Central & 02-486 Warsaw Kornél Szántó
3.613.715.331
Eastern Europe Einsteinova 24 kszanto@nissan-europe.com
Slovak Republic +421 2 3211 2401
851 01 Bratislava
Antala Staska 2027/77
Czech Republic +420 241 094 403
140 00 Prague 4-Krc
Sverige
Suomi Erik Van Rooij
Nissan Nordic Europe +358 (0) 10 770 5309
Danmark erikvanrooij@nissan-europe.com
Norge
Yuri Pavlov
Nissan Motor Rus Росия +7 495 961 2131 (ext 602)
ypavlov@nissan.ru
In countries without a specific structure for this purpose, please contact with your trusted NISSAN dealer. If needed,
the selected dealer will contact the relevant NISSAN department .

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Edition 4, May- 2016 NTCE – LCV Engineering

ENGINEERING BODYBUILDER STANDARDS

Edition: 4, May- 2016

1. INTRODUCTION 1 of 15 F91A MY13

1. INTRODUCTION 2 of 15 F91A MY13

1. INTRODUCTION 3 of 15 F91A MY13

1. INTRODUCTION 4 of 15 F91A MY13

1. INTRODUCTION 5 of 15 F91A MY13

1. INTRODUCTION 6 of 15 F91A MY13

1. INTRODUCTION 7 of 15 F91A MY13

1. INTRODUCTION 8 of 15 F91A MY13

1.1.2 Precautions and warnings

1. INTRODUCTION 9 of 15 F91A MY13

1.2 DELIVERY RANGE

The range has:

Gross Vehicle Weight (Kg) Engine type (Hp)

1. INTRODUCTION 10 of 15 F91A MY13

The main features of the NT400 / CABSTAR range vehicles are:

1. INTRODUCTION 11 of 15 F91A MY13

1.3. IDENTIFICACION OF MODELS

1. INTRODUCTION 12 of 15 F91A MY13

1.3.2 Frame number

Mexico VIN Model Code:

1. INTRODUCTION 13 of 15 F91A MY13

1.4. INFORMATION FOR BODYBUILDERS

1. INTRODUCTION 14 of 15 F91A MY13

1.5. TECHNICAL SUPPORT AND BODYBUILDERS INFORMATION

Company Bodybulder's support Telf Telf

1. INTRODUCTION 15 of 15 F91A MY13

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