CITROEN RELAY 2019 Handbook (in English)

179
DOUBLE CHASSIS CABDOUBLE FLOOR CAB
L3 L4 L2 L3L4
L Overall length 5,8436,208 5,7386,228 6,678
A Wheelbase 4,0353,450 4,035
B Front overhang 948948
C Rear overhang 8601, 2 25 1,3 4 0 1, 24 51,6 9 5
D Width (with/without mirrors) 2,508/2,050- / 2 ,1 0 0
- Body width --
- Max. permitted body width --
E Front track 1,8101,810
- Rear track 1,79 01,79 0
- Increased rear track 1,9 8 01,9 8 0
F Overall height 2,2542 ,1 5 3
- Max. permitted body height --
10
Special features

180
Tipper
Safety recommendations
The tipper body is raised by an electro-
hydraulic unit powered by the vehicle's battery.The tipper body is raised and lowered by
pressing and holding the corresponding
buttons on the magnetic and portable remote
control situated on a
support in the cab.
The tipper body is raised by the motor in the
electro-hydraulic unit.
The tipper body is lowered by a solenoid valve
that opens the fluid return of the ram.
A safety device prevents the tipper body from
dropping when it is not moving or is being
raised. •
N
ever drive with a drop panel lowered.
•
E
nsure that there is no person or
obstacle nearby (below or above)
when unloading.
•
N
ever leave the tipper body raised
when not in use.
•
A
lways discharge the load with the
upper part of the rear drop panel
secured.
•
O
bser ve the maximum payload on the
weight plate on the vehicle.
•
C
heck regularly that the suspension
is in good condition and that the tyres
are inflated to the recommended
pressures.
•

D
istribute the load uniformly in the
tipper body.
•
T

ransport similar products that
discharge easily.
•

N
ever drive, even slowly, with the
tipper body raised.
Tip onto a
sur face that is flat
and hard: a sur face that is
sloping or loose could cause
the centre of gravity to shift,
making the whole vehicle
unstable.
Special features

181
Characteristics
EquipmentDetails
Tipper Tipper base made of 2
strips of 2.5 mm thick zinc-coated high tensile
steel, joined by central and longitudinal laser welding.
Tipper body painted vehicle body colour.
Tipper structure 2
main longerons in galvanised high tensile steel.
1
tubular steel ram head cross member.
Cross members in galvanised high tensile steel. Protected against
corrosion by application of a
powder coating.
Sub-frame 2 "C" section longerons made of 2.5
mm thick high tensile steel, interior
strengthening by enlarged lower wings.
Fixing to the base vehicle by high tensile steel brackets.
1
machine-welded tubular steel ram foot cross member, hot galvanised.
1
rear articulation cross member in galvanised steel.
Stop brackets at the ends of the longerons.
Rear lamp protection grille.
Cycle guard and wing supports in galvanised steel.
Body sides Body sides in high tensile steel, 15/10
thickness, cold formed, assembled
by continuous laser welding.
Anti-corrosion protection assured by a
powder coating paint finish.
Catches with reinforced zinc protection integrated into the form of the
sides.
Ladder carrier Galvanised steel uprights. Panels and cross members in painted steel
with clinched bolts.
Electro-pump unit 12
Volts/2 kW.
Operating temperature range: -20
to +70°C.
Hydraulic ram Expansion type, nitride ram, 3 -section, dia.: 107
mm
Maximum pressure: 20
bar.
Hydraulic fluid Mineral type ISO HV 46
or equivalent.
Dimensions
This conversion is only available on the
L2 single cab; refer to the table below for the
characteristics of the tipper.
Tipper (in mm)
Load length 3,200
Overall length 3,248
Load width 2,000
Overall width 2 ,1 0 0
Height of body sides 350
Conversion weight (in kg) 550
For information on the characteristics
of the L2
chassis cab, refer to the
"Dimensions" section for the floor cab
model.
10
Special features

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

1
Touch screen Audio-Telematic system
Multimedia audio system –
Bluetooth® telephone – GPS
navigation
Contents
First steps

1
G

lossary
2
S

teering wheel mounted controls
3
M

enus
3
R

adio
4
D

AB radio (Digital Audio Broadcasting)
5
M

edia
6
N

avigation
9
T

elephone
1
2
Vehicle information

1
4
Settings

1
4
Voice commands

1
6The system is protected in such a
way that
it will only operate in your vehicle.
For safety reasons, the vehicle must
always be stationary for the driver to
perform operations that require close
attention.
When the engine is switched off and to
prevent discharging of the battery, the
system switches off after activation of
energy economy mode.
First steps
Use the buttons arranged below the touch
screen for access to the main menus, then
press the virtual buttons in the touch screen.
The screen is of the "resistive" type, it is
necessary to press firmly, particularly for
"flick" gestures (scrolling through a
list,
moving the map, etc.). A simple wipe will
not be enough. Pressing with more than
one finger is not recognised.
The screen can be used with gloves. This
technology allows use at all temperatures.
To clean the screen, use a
soft non-
abrasive cloth (e.g. spectacles cloth)
without any additional product.
Do not use sharp objects on the screen.
Do not touch the screen with wet hands.
In very hot conditions, the volume may be
limited to protect the system. This returns
to normal when the temperature in the
passenger compartment drops.
The system may also go into standby
(screen and sound completely off) for
a
minimum period of 5 minutes.
.
Touch screen Audio-Telematic system

2
Press: on/off.
Rotate: adjust the volume (each
source is independent).
Eject CD.
Screen off/on.
Mute/pause the volume.
Radio, rotate: search for a radio
station.
Media, rotate: select the previous/
next track.
Press: confirm the option displayed
in the screen.
Activate, deactivate, adjust certain
system and vehicle functions.
Abandon the current operation.
Go up one level (menu or folder).Glossary
System details Meanings/corresponding actions
VOLUME Adjust the volume by rotation.
RADIO Access the radio menu.
MEDIA Access the media menu and the different audio sources.
N AV Access the navigation menu.
PHONE Access the telephone menu.
MORE Access vehicle information.
BROWSE
TUNE
SCROLL Turn the button to:
-

m
ove in a menu or a list.
-

s
elect a radio station.
ENTER Confirm an option displayed in the screen by pressing.
Touch screen Audio-Telematic system

3
Steering wheel mounted controls
Activate/deactivate the pause
function of CD, USB/iPod and
Bluetooth
® sources.
Activate/deactivate the radio mute
function.
Switch the microphone off/on during
a


telephone call.
Push up or down: increase or
decrease the volume for voice
announcements and music sources,
hands-free and speaking texts.
Switch voice recognition on.
Interrupt a
voice message to start
a

new voice command.
Interrupt voice recognition.
Accept an incoming call.
Accept a

second incoming call and
put the current call on hold.
Switch on voice recognition for the
telephone function.
Interrupt a
voice message to issue
another voice command.
Interrupt voice recognition. Radio, push up or down: select the
next/previous station.
Radio, hold up or down: sweep
frequencies up/down until the button
is released.
Media, push up or down: select the
next/previous track.
Media, hold up or down: fast
for ward/back until the button is
released.
Reject the incoming call.
End the call in progress.
Menus
Radio
Select the different radio sources.
Activate, deactivate and adjust
certain functions.
Telephone
Connect a telephone by Bluetooth®.
.
Touch screen Audio-Telematic system

4
Vehicle information
Access to the exterior temperature,
the clock, the compass and the trip
computer.
Navigation
Enter navigation settings and
choose a destination.
Settings
Activate, deactivate, and configure
certain functions of the system and
the vehicle.
Media
Select from the different music
sources.
Activate, deactivate, and adjust
certain functions.
Radio
Press "RADIO " to display the radio
menus:
Press the 9
or: buttons briefly for an
automatic search.
Press and hold the buttons for a
quick search.
Pressing Pre-set
Press and hold the button to pre-set the current
radio station.
The current station is highlighted.
Press the "All" button to display all the pre-set
radio stations in the frequency band selected.
Navigate
-

L

ist of stations .
Select a
station by pressing once.
-

U

pdate the list according to reception.
-

P

ress the 5 or 6 buttons to scroll through
the radio stations received.
-

G

o directly to the desired letter in the list.
AM/DAB
-

C

hoose the band .
Choose the waveband.
Touch screen Audio-Telematic system