2016 CITROEN RELAY Handbook (in English)

263
HYdrAuLIc SYStEM
these precautions are mandatory for any work on the hydraulic
system.
●

When 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),
●

Never work under a tipper body that is not supported,
●


Switch of
f the power supply to the electro-hydraulic unit using
the circuit breaker,
●

V
ehicle stationary, engine off.
As a safety measure we strongly advise against doing anything
under the tipper body while it is being operated or while it is
being serviced.
SPECIAL FEATURES
Tipper body

264
SErVIc I n G
r eservoir
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 servicing, the ball bearings are lubricated for life and
the plain bearings by the pumped fluid.
Lubrication
The tipper body and ram pivots do not have grease nipples.
Lubricate regularly the hinges and retainers for the tipper body sides
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 hose.
Touch-in the paint chips quickly to avoid the spread of rust.
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
● Remove the plug 244A taking care to recover the ball.
●
Using a wide screwdriver
, remove the bore / piston bolt
assembly.
●

Check that the piston slides smoothly and remove any

impurities. Pass a magnet over if there is any swarf present.
●

Refit the assembly and ensure that the piston slides smoothly
.
Retain the ball with some grease on the plug for reassembly.
●

Bleed the hydraulic system.
Bleed the electro-hydraulic unit
● Remove the hexagonal plug 257.
●
Slacken by a half turn the bolt
587 located inside, using a
hexagonal 6 mm spanner.
●

Operate the electro-hydraulic unit for a few moments by

pressing the raise button.
●

The tipper body does not rise, or very slowly
. When fluid flows
from the orifice, the system is bled.
●

Retighten bolt
587 and refit the plug 257, check that the tipper
body lowers correctly.
Tipper body

265detailled view of the ud2386 electro-hydraulic unit
SPECIAL FEATURES
Tipper body

266
dIAGnOSIS
SymptomElectricalHydraulic Verification / c heck
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 reservoir.
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 "Servicing" section.
X No, check the return valve winding and electrical connections.
X No, replace the electrovalve.
X No, check the alignment of the ram.
Tipper body

267
SymptomElectricalHydraulic Verification / c heck
The unit operates but
does not generate
pressure. X
Valve slider jammed if no electrovalve on the unit.
Refer to the "Servicing" 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. XElectrovalve jammed, replace it or tighten the nut behind

the strainer.
The control unit does
not operate. X
Check the connections and contacts.
Emulsion in the
reservoir. X
Return pipe incorrectly fitted.
X Fluid level to 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 when
going down. X
Replace the return valve winding.
SPECIAL FEATURES
Tipper body