TECHNICAL NOTE

Edition Anglaise
JANUARY 1998
77 11 197 869 467AService 0422
Type S/Section

MASTER XXX X 45 56

56 SPECIAL POINTS FOR VERSIONS OF THE MASTER WITH A TIPPER AND HIGH ROOF

• Engine : XXX
• Gearbox : XXX Basic manual : M.R. 324

This note contains the special points you need to know when removing and refitting the
tipper unit and the raised roof on the MASTER .

"The repair methods given by the manufacturer in this document are based on the
technical specifications current when it was prepared.
The methods may be modified as a result of changes by the manufacturer in the
production of the various component units and accessories from which his vehicles
are constructed".
All copyrights reserved by Renault.
Copying or translating, in part or in full, of this document or use of the service part
reference numbering system is forbidden without the prior written authority of
RENAULT.

C RENAULT 1998
 EXTERIOR ACCESSORIES
Tipper unit 56
Place the vehicle on a two-post lift to remove the Disconnect the battery+ or use the battery dis-
tipper. connector.

Check the lifting capacity (3.5 tonnes).
REMOVING THE TIPPER
ATTENTION : Fit safety stay Car. 1483 in position.
Place a block of wood between the hydraulic jack
and the side member of the dummy chassis
Remove shaft (B).
Disconnect chain (C) from the unlocking hook.

Remove :
- the split pins on the rear shafts (D),
- the shafts (E).

14448R

Remove the split pin (A) from the shaft on the

head of the hydraulic jack.

14451R
Lower the tipper unit again.

Use a vehicle lift to raise the tipper unit.

REFITTING

Proceed in reverse order to removal.

14450R

56-1
 EXTERIOR ACCESSORIES
Tipper unit 56
REMOVAL OF THE DUMMY CHASSIS REMOVING THE HYDRAULIC JACK ON ITS OWN

First remove the tipper unit and then disconnect ATTENTION: Fit safety stay Car. 1483 in position
the wiring harness (front section). before starting any work.

Remove from the dummy chassis the mounting
studs securing cyclist protector strips and the wing
mountings .
Disconnect the battery + or use a battery dis-
connector.
Remove the split pin and the shaft from the head
of the hydraulic jack.

Position a container to catch the oil.

Disconnect the swivel connection for the hydraulic

line.

Plug the end of the pipe.

Remove :
- the mountings for the left-hand bearing,
- the hydraulic jack.

14448R1

14449R

56-2
 EXTERIOR ACCESSORIES
Tipper unit 56
REPLACING SEALS (This operation must be performed with great care and attention to cleanliness.)

First remove the hydraulic jack,. Then, using a pin spanner, remove the base of the hydraulic jack (1) (For
example: spanner FACOM 117A + fittings 117E4).

Remove spring ring (2) (flat screwdriver) and extract parts (3, 4 and 5).

Remove lip seals (A) and O-ring (B) from the base of the hydraulic jack.

Clean the seal grooves.

14454R

REFITTING Refit the split pin.

Take care to refit the lip seals in the right direc-
tion (A) (lips point towards exterior).
Refit the parts of the hydraulic jack.
Change seal (B) and then screw down the base
again.
Take away the safety stay and move the tipper
unit several times. (The hydraulic circuit will be
bled automatically.)
Top up the oil level. (The oil level in the reservoir
must be 55 mm, with the tipper unit in the fully
raised position.)

Refit the hydraulic jack and secure the bearing. Oil : ELF OLNA DS46
or
Reconnect the hydraulic line. ELF HYDRELF DS46
(to be ordered from ELF).
Connect the battery or the battery disconnector.

Move the hydraulic jack around so that the shaft

for the hydraulic head can be fitted.

56-3
 EXTERIOR ACCESSORIES
Tipper unit 56
REMOVING THE ELECTRIC PUMP UNIT Changing the oil or replacing or cleaning the
strainer
ATTENTION: Fit the safety stay: Car. 1483.
ATTENTION: Fit the safety stay Car. 1483 in posi-
Disconnect the battery + or use a battery dis- tion.
connector.
Place a container in position to catch the oil (can-
Disconnect the wiring harness (A). not be reused).

Disconnect the union (B) on the hydraulic line. Remove the rear mounting (C) for the reservoir.
(Seal the end.)
Remove the four bolts (D) securing the reservoir
Remove mountings (C). to the pump.

Remove the reservoir.

14449-1R

14449R1

REFITTING Reservoir capacity: 6 litres (The oil level in the

reservoir must be 55 mm with the tipper unit
Proceed in reverse order to removal. raised and 120 mm with the tipper lowered.)

Move the tipper unit to bleed the hydraulic Oil: ELF OLNA DS46
circuit. or
ELF HYDRELF DS46
(to be ordered from ELF).

56-4
 EXTERIOR ACCESSORIES
Tipper unit 56
REFITTING Adjusting the pressure

Proceed in reverse order. Remove nut (B).

Move the tipper unit to bleed the hydraulic Tighten or slacken off adjusting screw (C) until the
circuit. specified pressure of 80 ± 5 bars is obtained.

Press button D on the control unit to make

the pressure drop.
Checking the hydraulic pressure
Refit nut (B).
Tooling: Pressure gauge 0-250 bars with rotating
union 8 x 13. Remove the pressure gauge.

Disconnect the hydraulic line (A) where it leaves Reconnect the line.
the hydraulic assembly. (Seal the end of the line.)
Check the oil level.
Connect the pressure gauge at the union (A).

Press button M on the control panel.

Read the pressure which should be approximate-

ly: 80 ± 5 bars

14449R2

56-5
 BODY TOP
Raised roof 45
The raised roof is secured by bolts and mastic Use piano wire to cut through the mastic.
adhesive.
Start at a corner of the front section.

REMOVING Remove the raised section (minimum of five peo-

ple).
First remove the interior trim in the cab and then
take off mountings (A) and (B).
Preparing a new unit

Prepare the area where the adhesive is to be ap-

plied (P120).

Blow clean and degrease (heptane).

Apply primer to the area where adhesive is to be

applied using the sheet metal primer (green
bottle).

Wait a minimum of 10 minutes before applying

adhesive.

The preparation work required on the outer skin

is similar to preparing a window aperture for fit-
ting glass.

Minor repairs can be carried out (see the section

on "Repairing SMC heat-shrink components" in
14453R the manual on "Plastics" in M.R. 502).

14452R

45-1