Mercedes-Benz 410 D, 410, 310, 408 D, 308 D Operating Instructions Manual

...

Operating Instructions

® Mercedes-Benz

Operating Instructions

208 D 210 D 210 308 D 310 D 310 408 D 410 D 410

Notes concerning vehicle safety

We recommend that

- only MERCEDES-BENZ original parts and conversion parts and accessories expressly approved for the respective vehicle model by MERCEDES-BENZ should be used. Safety, rehabihty and suitability of these parts have been determined in a special test;

- bodies should be made and mounted in compliance with current MERCEDES-BENZ Body/Equipment Mounting Directives. Only in this way is it ensured that chassis and body form a unit and that optimum operational reliability and roadworthiness is offered.

We cannot be held liable for reliability, safety and suitability if

- original parts or approved convers ion parts and accessories have been replaced with other parts or if other modifications have been made to the vehicle;

- bodies have not been manufactured or mounted in compliance with current

MERCEDES-BE NZ Body 'Equipment Mounting Directives, or if in the case of deviations from these directives the approval of MERCEDES-BENZ has not been obtained.

Approval granted by public testing agencies or officia l authorizations do not rule out safety hazards.

Every MERCEDES-BENZ service station will offer further information.

Printed in Germany

We reserve lhe nght to modify the technical details as given 1n the data and illustrations of these Operating Instructions (s.e.e.o.).

Reprinting, translation and copying, even of excerpts, 1s not permitted without our prior

authorization 1n wnttng.

VKT 8.89.10 RU

The se Operating Instructions are designed to provide clear answers to essential questions concerning operation, service and maintenance.

In some sections you will in addition find instructions for the economic operation of your vehicle. By complying with these instructions you can assist in effectively reducing the fuel consumption (energy

consumpt ion). Operating Instructions and Maintenance Booklet are important

documents which should always be carried in the vehicle. To ensure continuous operational reliability and roadworthiness, we

strongly recommend that service and maintenance work listed in the Maintenance Booklet be carried out on time.

For this purpose, an extensive network of MERCEDES-BENZ service

stations is at your disposal.

Before operating the vehicle for the first time, please refer to the sections entitled.

,,Components" and ,,Operation".

Several vehicle types whose principal components are identical are dealt with in these Operating Instructions . Besides this important optional extras are included. Your vehicle may therefore differ from some of the descriptions and illustrations.

We wish you good motoring!

Mercedes-Benz Aktiengesellschaft

Contents

Data car ds/ident ification plates

2 Component s .................. . ..... .

2.1 Door control, front ................ .

2.2 Driver's seat adjustment . . ...... . .. .

2.3 Seat belts ...................... .

2.4 Instruments and controls ........... .

2.5 Tachograp h .......... . ......... .

2.6 Battery master switch . ............ .

2. 7 Steering lock tstarter switch ......... .

2.8 Light switch ..................... .

2.9 Combinat ion switch ............... .

O Headlight beam con trol . ........ . .. .

2.1

2.11 Interior light ..................... .

2.12 Interio r mirror ................... .

2.13 Seat lock - assistant driver's seat

2.14 Headrest ........... . ... . ....... .

2.15 Seat heater ............. . ....... .

2. 16 Heating and ventilation .... . .. . .... .

2. 17 Supp lementary heater .. . .......... .

2.18 Door control - cargo space ......... .

2. 19 Engine cove r ..... . .............. .

2.20 Engine com partment flap ... . .. . .... .

3 Operation ... . ............... . ... . . . .

3. 1 Preparations for driving ............ .

3.2 Starting and shutting off the engine

3.3 Hand brake operation ............. .

3.4 Starting the vehicle and shifting gears

3.5 Breaking in .................. . .. .

3.6 General driving instructions ...... . . . .

3.7 Anti-lock braking system (ABS) ...... .

3.8 Trailer ..................... . ... .

3.9 Winter ope ration ................. .

Page

12 14 14 15 15 16 17

17 18 18 19

20 22 24 28 29

30 30

36 39 39

44 45

4 Service products .................. . .. .

4.1 Engine oils ....... . ........ . ... .

4.2 Coolant ...... . ................ .

4.3 Diesel fuels . ................... .

4.4 Capacit ies - summa ry ............ .

5 Vehicle service and maintenance ........ .

Vehicle tools and emergency equipment

5.1 Engine ...................... . .

5.1. 1 Technical data ................... ·

5.1.2

5.1 .3 Oil and filter change .............. .

5.1 .4 Renewa l of air cleaner element

5.1.5 Poly-V-belt . . .................. .

5.2 Fuel system .......... . .. . ... . . .

5.2.1 Fuel prefilter .............. . .... .

5.2.2 Replaci ng the fuel filter element . .... .

5.2.3 Bleeding the fuel system .......... .

5.3 Cooling system ................ .

5.3.1 Check ing radiator for soiling, cleaning . .

5.3.2 Draining and replenishing coo ling syste m

5.4 Clutch

5.5 Transmission .......... . ....... .

5.5.1 Manual transmission ..... . ... . ... .

5.5.1.1 Tightening torque ................ .

5.5.1.2

5.5.1.3 Cleaning breather .. ... .......... .

5.5.2 MB automatic transmission ......... .

5.5.2.1 Tighten ing torques ............ . .. .

l ightening torques ... . ........... .

0 11 level check and oil change ...... .

Page

52 52 53

59 60

61 61 63 63

67 67 67

69 69

1e i2

i2 i3 i4 i7

;1 ;1

;3 ;5

;7 ;7 ;7

i8 i8

;9 ;9

!.>.5.2.2 Oil level check ...... . ..... . .... .

5.5.2.3 Oil and filter change ............. .

5.6 Front axle .................... .

5.6.1 Tightening torque .......... . .... .

5.7

5.7.1

5.7.2

5.8

5.8.1

5.8.2

5.8.3

5.8.4

5.9

5.9.1

5.9.2

5.9.3 ~.10

5.10.1

5.10.2

5.11

5.11.1

5.11.2

5. 11.3 Fuses ....................... .

5. 11 .3. 1 Testing fuses .. . ............... .

5. 11 .4 Battery care ................... .

5.11 .5 Checking the headlight setting

Rear axle ......... . .......... .

Tightening torques .............. .

0 11 level check and oil change

Steering ..................... .

Technical data .............. . .. .

Tigh1ening torques ...... . ....... .

Checking oil level ............... .

Checking the toe-in . ........... .

Wheels and tires .............. .

Tightening torques .............. .

Spare wheel location .... . ....... .

Wheel change ................. .

Brake system ............. . ... .

Checking the brake lines . ........ .

Checking brake padtlining thickness

Electrical system .............. .

Technical data ................. .

Power collection - additional

consuming units ................ .

Page

72 73

74 74

74 74 74

75 75 75 76 76

77 77 77

78 79

79 79

80 80

80 81 81 82 83

5.11.6

5.11.7

5.11.5

5.11.9

5.11.10

5.12 Chassis and body ..... . ........ .

5.12.1 Inspec tion and maintenance of trailer

5.12.2 Ad1ustment of side board locks ..... .

5.12.3 Lubrica tion .................... .

5.13

5.14 Preparing the vehicle for storage

5.15 Preparing the vehicle for service

6 Troubleshooting .............. . ...... .

6.1 Engine and fuel system .......... .

6.2 Clutch . . ..................... .

6.3 Steering .......... . ........... .

6.4 Brake system ... . .............. .

6.5 Electrical system ............... .

6.6 Supplementary heater . .......... .

6.7 Jump starting ....... . .......... .

6.8 Shutting off the engine when the

6.9 Fan with fluid coup ling ........... .

6.1 O Tow-starting and towing the vehicle

Tire pressure chart

Headlight bulb replacement ....... .

Three-phase alternator .... . ..... .

Visual inspec tion of spark plugs

Bulbs - summary . . ... . ......... .

Wmng diagrams ....... . ..... . .. .

coupling ...................... .

Vehicle cleaning and care

after storage .................. .

vacuum system is faulty .......... .

Page

83 84 84 85 86

103

103 103

103 104

105

106

107 107

109

110 111 112 113

114 114

115 116

1 Data cards/identification plates

With the vehicle you are handed over data cards listing all the impor tant vehicle

data (e. g. vehicle identification number and component numbers including mode l and designat ions of the special equipment , etc.). These data are required when ordering spare parts or inquiring for technical details.

Body number , paint code no on left side front cab post

Card no.

For safety reasons th is card must not be kept in the vehicle. It lists the key

numbe rs for the order ing of replacement keys. Card no. 2

This card (without key numbers ) 1s kept in the Maintenance Booklet.

210 - 410 Engine cover opened

1 Engine no on L-H engine side

2 Components

2.1 Door control, front (example)

Hinged door

Door control, outside

1 Locked

2 Unlocked

To open the door, press in door lock cylinder

Door and window control, inside

1 Door latch unlocked 2 Door latch locked 3 Opening lever, door 4 Window crank

5 Vent window lock (push button to unlock)

Sliding door

Door control, outside 1 Locked 2 Unlocked 3 Opening lever

Press opening lever, grip handle and push door fore (aft) until the lock

engages.

Door control, inside 1 Opening lever

Actuate openig lever, grab lever and push door fore (aft) until the lock engages.

2.2 Driver's seat adjustment

Standard version

1 Height of seat, front portion 2 Forward and rearward 3 Height of seat, rear portion 4 Seat back

Make lsringhausen

1 Forward and backward adjustment 2 Height of seat, front portion 3 Height of seat, rear portion 4 Seat back position

5 Seat load

1 Tongue 2 Bucl<le 3 Button

2.3 Seat belts (example)

These instructions are only applicable to belts which were installed at the manufacturing plant of the vehicle. Forv subsequent installation use only seat belts approved by us.

Notes:

- Use each safety belt for only one person.

- Three-po int belts are not intended for children up to a size of approx. 140 cm.

- Seat belts which are subjected to severe strain during an accident must be renewed. Inspect belt anchorages.

- Renew damaged seat belts.

- Changes which impair the effectiveness of the belt may not be carried out.·

- Belt webs may not be directed over sharp edges.

- For cleaning and care of belt webbing, refer to section 5. 13.

Seat belts with inertial reels

Three-point seat belt

Fastening:

- Pull belt with tong ue (1) over shoulder and lap. The belt must not be twisted.

- Press tongue (1) into buckle (2) and allow to engage audibly.

- The belt must be tight. Check this condition immediately after having fastened it and regularly while driving. If necessary , tension lap belt by pulling the upper belt section upwards.

Unfastening:

- Push red button (3) in buckle.

- Return tongue ( 1 ) to initial position.

Its

Lap belt

- Pull belt by tongue ( 1) over the lap, press tongue into buckle (2) and allow to engage audibly. The belt must not be twisted but must fit snugly.

- To unfasten the belt, push button

(3) ,n buckle.

Inertia reel operat ion The inerai reel of the seat belts stops the belts unwinding further in case of

vehicle deceleration in any direction and if the belts is pulled out quickly. The locking function of the inertia reel can be checked by braking, by cornering or

by pulling the belt out quickly.

Seat belts without automatic retraction unit

Lap belt

- Pull belt with buckle latch (1) over the lap, engage in the buckle (2) and engage audibly. The belt may not be twisted and must hug the body. Shortening the belt: Engage buckle latch in the buckle.

Pull the belt end until taut. Extending the belt: Press the buckle latch into the buckle latch housing and

adjust the belt web to the desired length.

- For loosening the belt press the red button

(3) in the buckle.

2.4 Instruments and controls

'{ 21

-.....,_"\\

Vent1lat1on and defros ting nozzles for side windows

(page 20) 2 Light switch (page 15) 3 Coolant temperature gauge (page 46) 4 Indicator lights 5 Speedometer or tachograph (page 6 Selector lever pos1t1on indicator - MB automat ic

transmission (page

7 Choke control 8 Switches 9 I lea1ing and ventilation (page

1 :>

41) or fuel gauge

210, 310, 410 (page 37)

14)

20)

10 Plug socket 11 Glove box 12 Cover, fuse box (page 81) 13

Radio

14 Ashtray 15 Engine cover (page 28) 16 Clock 17 Steering lock starter switch (page 15)

18 Horn

19 Fuel gauge or operating hour meter

20 Combination switch (page 16) 21

Lever, engine compar tment flap (page 29)

I liyh beam

ABS (page 48)

Iii]

filij

5-Xi 5-Xi

Ill

~witches

Interior light - bus D1fferent1al lock, rear axle (page 42)

Choke control (page 37)

Preglowing (page 36) Turn signal indicator light - tractor Turn signal indicator light - trailer

Rotary flashing beacon

Step

Blower (page 20) Heated rear window

Rotary flashing beacon

Dump body

•

lrn

Iii

t?J

Shift lock power take-off, (page 43)

Charge indicator light (page 46)

Brake fluid and brake pad wear (page 46)

Oil pres sure - engine

Heated rear window

Supplementary heater - operat ion indicator light

(page 22)

•

[ii.] Interior light - bus

la Dump body

M Hazard warning flasher system with indicator light

Seat l1eater (page

19)

m Supplementary heater (page 22)

2.5 Tachograph (examp le)

1 Time group knob 2 Speedomete r 3 Speed warning light 4 Clock function control light 5 Function cont rol light

2.6 Battery master switch

Battery master switch on seat base

1 Switched on

All consu ming units can be switched on.

2 Switched off

All consum ing units are disconnec ted from the battery. The actuation lever can be pulled off.

2.7 Steering lock/starter switch

Steering lock

0 In this position the key can be inserted or removed.

When the key 1s withdrawn, the steering is locked.

1 Steering unlocked

2 Driving position

3 Starting position

Caution! Never lock the steering if the vehicle is rolling.

Starter switch 0 In this position the key can be inserted or removed. 2 Driving position 3 Starting position

2.8 Light switch

0 Off position

1 Parking lights

2 Headlights

(Vehicles with automatic headlight switch-off system: Only while the engine is running and the charge indicator light has gone out).

3 Standing lights, right

:;i 4 Standing lights, left

c, B Fog lights plus rear fog light with indicator light on in positio n 1 or 2

A Fog lights on in position 1 or 2

2.9 Combination switch

Low beam 2 High bea m 3 Headlight flasher 4 Turn signal lights, right

Up to point of resistance

Beyond point of resis tance (engagement)

5 Turn signal lights, left

Up to point of res istance

Beyond po int of resistance (engagement)

6 Windshie ld wiper

,,O" Switched off ,,I" Intermittent wiping ,,II" Low speed ,,Ill" High speed

7 Windshield washer system - headl ight cleaning system

Press switch = switched on. The headlight cleaning system (optional) is only operated when the veh icle lights are switched on. Check wiper blades regula rly for soiling and damage.

= brief flashing.

= continuous flashing.

= brief flashing.

= continuous flashing.

2.10 Headlight beam control

0 Norma l position

I Vehicle with maximum load (with evenly spread load)

II Vehicle with maximum load (with large part of load shifted to rear axle)

2.11 Interior light

Switch positions

1 On

2 Off 3 Light is switched on and off by the· door contact.

2.12 Interior mirror

Operating lever

1 Normal position

2 Dimmed position

2.13 Seat lock - assistant driver's seat

1 Unlocking, right

2 Unlocking , left Operate lever, tilt seat forward or

backward until lock engages .

2.14 Headrest (example)

~r's

Height and inclination of headre st can be adjusted.

-~n=~ . ·::::;::mrc::;:t:[J:I'n'i}:f

;;;.:::::::::;,:::: '.•:-//::::,

2.15 Seat heater

Control switch Press upper end (II) Center position Press lower end

If the engine is off, do not engage po~ition ,,fast heating" for longer than is

abso lutely necessary.

= fast heating

= switched off

(I) = continuous operation

2.16 Heating and ventilation

Control levers are infinitely variable

Blower switch Press upper end (II) Center position Press lower end (I) = speed 1

2 Air flaps for windsh ield (ventilation or defrosting)

Lever positions: left closed

3 Water control valve

Lever positions: left = cold

right

= speed 2 = off

= open

= warm

4 Air flaps for footwell (ventilation or heating)

Lever positions: left

5 Ventilation and defrosting nozzles 6 Ventilation and heating nozzles 7 Ventilation and defrosting nozzles, adjustable.

The nozzles can be opened and closed with the lever in the nozzles.

right

= closed = open

t 1tt11u mcurnples

W1111l11w rh1lrosting : Heater fully on:

NS )().:1

Ven tilat ion fully on:

J'l

ver

1 Switch, supplementary heater

2 Lever, heater water control

valve

2.17 Supplementary heater (optional extra)

The supplementa ry heater can be operated with the vehicle engine shut off or running.

Switch on supplementa ry heater for approx. 5 minutes at least once a month.

Hot-air supplementary heater

Switching on:

- Switch on battery master switch (optional extra).

- Press supplementary heater switch at lower end. The operation indicator light on the instrument panel comes on. After approx. 2 minutes the heater will start

Switching off:

- Press supplementary heater switch at upper end. The operation indicator light goes out. The heater is cut out automatically after a 2 minute lag.

Hot-water supplementary heater

Switching on:

- Switch on battery master switch (optional extra).

- Push heater control

- Press supplemen tary heater switch at lower end. The operation indicator light on the instrument panel comes on. After approx. 1 minute the heater will start.

valve lever all the way to the right.

Switching off:

- Press supplementary heater switch at upper end. The operation indicator light

goes out. The heater is cut out automatically after a

21/2 minute lag.

art.

rt.

11111111 ·,upplementary heater

11h11,,<1 freld

I (

I t11volvrng dial

t ',111t111r, knob

II • ,w111 h, dral illumination

I 11 •,wrtch on, press in switch and

111111 to the right

Io •;wrtch off, turn switch to the

h•II

Timer (hot-water supplementary heater, optional extra)

1 Programmed heating

Switching on: Example: The supplementary heater is to start at

the time switch should be set at

- Set rotating dial to have graduation

18:00 hours on the previous evening.

18 coincide with the right edge of the

colored field.

- Turn setting knob with its pointed end clockwise beyond graduation Then reverse it to 10.

- The heater switches itself on automatically at the preselected time. The

operation indicator light on the instrument panel comes on.

Switching off:

- Turn setting handle counterclockwise to the end of the colored field.

When doing this, some resistance must be overcome . Caution: Do not apply force when turning the setting knob. The operation indicator light goes out. The heater is automatically switched off

after an approximate

- After a maximum of

2112 minute lag.

1 hour the supplementary heater switches off automatically.

2 Immediate heating

Switching on:

- Turn setting knob clockwise beyond the colored field and then reverse to the right edge of the colored field. The operation indicator light on the instrument

panel comes on. After approx.

1 minute the heater will start.

Switching off:

- Turn setting handle counterclockwise to the end of the colored field. When doing this, some resistance must be overcome.

Caution: Do not apply force when turning the setting knob. The operation indicator light goes out. The heater is automatically switched off approximately after a

- After a maximum of

1 hour the supplementary heater switches off automatically.

10:00 hours the next morning,

10.

21/2 minute lag.

21~

2.18 Door control - cargo space

Rear. door

Door control, outside (example)

1 Unlocked

To open the door, press in door lock cylinder

2 Locked

Door control , inside

1 Door latch unlocked 2 Door latch locked 3 Opening lever of 1 st door 4 Lock of 2nd door

To open , swing handle up.

Van with high roof

Opening angle 90°

1 Locking hook

Open door 90° and engage locking hook.

2 Clamp

Fasten locking hook before closing the door.

Opening angle 180°

1 Locking hook

2 Door check

Disengage locking hook, swing door check inward. Open door 180° and engage locking hook. Prior to closing the door, engage door check. Attach locking hook.

Opening angle 270°

1 Door lock

Disengage locking hook, swing door check inward. Open door 270°. Engage lock. To unlock, pull forward latch 1n the door lock. Prior to closing the door, engage door check. Fasten locking hook.

Sliding door (example}

Door control, outside

1 Locked

2 Unlocked To open the door, press 1n door lock cylinder, grab handle and push door

rearward to the stop.

To close the door, grab handle and push door forward until the door lock engages.

Door control, inside

1 Door latch unlocked

! 2 Door latch locked

3 Opening lever, door

Childproof lock (rear door and sliding door)

Actuate safety catch (e. g. with the steering lock key)

1 Unlocked

2 Locked

The door can be opened from outside only.

2.19 Engine cover

Opening the engine cover

1 Clamp Note: Prior to the detachment of the>

Pngrne cover, remove driver's seat.

2.20 Engine compartment flap

Opening the engine compartment flap

1 Lever

2 Safety hook

- Operate lever The engine compartment flap opens to the stop of the safety hook.

- Actuate safety hook

- Swing engine compartmen t flap up until the catch engages.

Closing the engine compartmen t flap 3 Safety catch

- Lift engine compartmen t flap

- Unlock catch

- Swing down engine compartment flap and engage

tn lock.

+ 90 hidden pages

Mercedes-Benz 410 D, 410, 310, 408 D, 308 D Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual