maintenance CITROEN RELAY 2019 Handbook (in English)

169
2 - SAFET Y
The use of original parts, fluids and lubricants
and compliance with scheduled maintenance
guarantee your vehicle's reliability and safety
over time.
3 - DANGERKEEP OUT OF CHILDREN'S REACH KEEP AWAY FROM FLAMES DO NOT TOUCH
DO NOT OPEN CAP WITH THE ENGINE WARM EXPLOSION
CORROSIVE LIQUID
MAY START AUTOMATICALLY EVEN WITH ENGINE OFF HIGH PRESSURE GAS DO NOT OPEN
AUTOMATIC ENGINE RESTART. TAKE OUT THE IGNITION KEY WHEN THE BONNET IS OPENED. HIGH VOLTAGE
9
Technical data

182
Weights and towed
loads (kg)
With load transfer, the braked trailer weight can
be increased, on condition that the equivalent
of this load is removed from the vehicle so that
the GTW is not exceeded. Warning: towing with
a lightly loaded towing vehicle may have an
adverse effect on its road holding.
The kerb weight is equal to the weight without
load + driver (75
kg) + fuel tank filled to 90%.
Hydraulic system
These precautions are mandator y for any
work on the hydraulic system. Before towing a trailer, check that:
-
t
he nose weight on the towbar ball does
not exceed the value (S) indicated on the
trailer's weight plate,
-
t
he maximum trailer weight is less than
the value indicated on the trailer's weight
plate and the Gross Vehicle Weight (GV W)
does not exceed the value indicated on the
vehicle's weight plate.
-
i
n the case of a self-supporting trailer,
the Gross Train Weight (GTW) must not
exceed the value indicated on the vehicle's
weight plate.
•
N
ever work under a tipper body that is not
supported,
• S witch off the power supply to the electro-
hydraulic unit using the circuit breaker,
•

V
ehicle stationary, engine off.
•

W
hen carrying out maintenance work
under the tipper body, place the tipper body
in the safety position secured with its stay
(position indicated by a red arrow under the
back of the tipper body),
Special features

183
Check and top up the fluid level regularly.
Replace the fluid annually. Replace the fluid if it
contains water.
Check the condition of the hydraulic hose and
the sealing of the hydraulic system regularly.
Pump and motor
Requires no ser vicing; the ball bearings are
lubricated for life and the pump bearings by the
pumped fluid.
Lubrication
The tipper body and ram pivots do not have
grease nipples. Lubricate the hinges and
retainers for the tipper body sides regularly,
as well as the catches for the rear tipper body
side.
Sub-chassis and tipper body
For maximum life, we recommend that you
clean your tipper body by washing it down
regularly with a hose.
Touch up paint chips quickly to avoid rust
spreading.After 8
months of use, check the
tightening torque of the fixings of the
underbody to the chassis (following the
recommendations of the body converter).
Cleaning the valve slider
F Loosen the cap 244A paying attention to
the ball and retrieving it.
F

U
sing a wide screwdriver, unscrew the
bore/piston bolt assembly.
F

C
heck that the piston slides smoothly and
remove any impurities. Pass a
magnet over
if there is any swar f present.
F

R
efit the assembly and ensure that the
piston slides smoothly. Retain the ball with
some grease on the plug for reassembly.
F

B
leed the hydraulic unit.
Bleeding the electro-hydraulic
unit
F Remove the hexagonal plug 257 .
F S lacken by a half turn the bolt 587 located
inside, using a
6 mm Allen key.
F

O
perate the electro-hydraulic unit for a few
moments by pressing the raise button.
F

T
he tipper body does not rise, or rises very
slowly. When fluid flows from the orifice,
the system is bled.
F

R
etighten the bolt 587

and refit the plug
257 . Check that the tipper body lowers
c o r r e c t l y.
Detailed view of the UD2386 electro-
h ydraulic unit
Maintenance
Reser voir
For safety reasons, we strongly advise
against doing anything under the tipper
body while it is being operated or while it
is being serviced.
10
Special features

184
Troubleshooting
SymptomsElectricalHydraulic Verification/Check
The hydraulic unit does not operate. X
Power supply harness and relay.
X Control harness (control unit).
X Circuit breaker.
Unit very noisy, body rises slowly. X Pick-up strainer blocked or squashed at the bottom of the reser voir.
New unit very noisy, body rises quickly. X Pump alignment, change the unit.
The ram goes down on its own. X Return valve squashed or jammed.
The ram does not go down. X
Yes, check the valve slider and bleed.
Refer to the "Maintenance" section.
X No, check the return valve winding and electrical connections.
X No, replace the solenoid.
X No, check the alignment of the ram.
The unit operates but does not
generate pressure. X
Valve slider jammed if no solenoid on the unit.
Refer to the "Maintenance" section.
X Pressure relief, adjustment, cleanliness.
X Pump seal failed.
X Motor/pump coupling.
X Pump loose on its bracket.
The hydraulic unit does not operate. X Solenoid jammed, replace it or tighten the nut behind the strainer.
The control unit does not operate. XCheck the connections and contacts.
Emulsion in the reser voir. X
Return pipe incorrectly fitted.
X Fluid level too low.
Fluid discharged from the breather. X Too much fluid.
X
Breather diaphragm tolerance a
little wide, to be replaced.
Only valid for UD2386
units.
The fuse blows while lowering. XReplace the return valve winding.
Special features