Mercedes-Benz 209 D User manual

207D 209D
307D 309D
407D 409D
OperatingInstructions I
J

Mercedes-Benz
OperatingInstructions
Mercedes-Benz
service
......
207D 209-D
307D
~ 309D
407D 409D

Printed in Germany
We reserve the right to modify the technical details as given in the data and illus-
trations of these Operating Instructions (s.e.e.o.).
Reprinting, translation and copying, even of excerpts, is not permitted without
our prior authorization in writing.
ZKD/ 1.83.3/Ru

These 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 comply ing with these
instructions you can assist in effectively reducing the fuel con-
sumption (energy consumption).
To ensure continuous operational reliability and roadworthi-
ness, 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 disposa l.
Before operati ngthe vehicle for the firsttime,please referto the
sections entitled
"Components" and "Operation"
Several vehicle types whose principal components are identi-
cal are dealt with in these Operating Instructions.
Besides this important optional extras are included. Your ve-
hicle may therefore differ from some of the descript ions and
illustrations.
Wewish you good motoring!
Daimler-Benz Aktiengesellschaft
3

Contents
Components
11
1 2
1 3
1.4
1.5
1 6
1 7
1.6
1 9
110
1.11
1.12
1 13
1.14
1.15
1.16
117
1 16
1.19
Door control front .
Driver's seat adjustme nt
Seat belt .
Instruments - summary .
Indicator lights and switches
Light switch ....
Combination switch ..
Steering lock
Tachograph
Radio
Heating and ventilation
Headlight beam contro l
Interior light
Interior mirror . . .
Seat lock - assistant driver's seat .
Headrest ..
Door control - cargo space
Engine cover
Engine compartment flap .
2 Operation
2.1
22
2.3
24
25
2.6
2.7
26
Preparallons for driving
Starting and shutting off the engine
Hand brake operation
Starting the vehicle and shifting gears
Breaking-in ..
Driving and braking
Trailer ..
Winter operation ..
3 Fuels, coolants, lubricants, etc.
4
3 1
32
33
Diesel fuels
Engine oils
Coolants
Page
6 4
6
7
7
6
10
12
12
13
13
14
16
16
16
16
19
20
20
22
23
24
24
29
30
30
33
34
37
36
40
40
41
42
Page
The vehicle, service and maintenanc e 43
4 1 Engine 45
4 1 1 011,incl liltur ch,inno 45
412 lnsprn llnq unct smv1c:u1u,11,dn11110, 46
413 nornovt1Innd in&t lllullon ol <.yllnclPr hcild cover 47
414 AdJU.Jt1nuv»lvn CIP tr IIICtJ ...... . . 47
4.2 f uel ay111,un 46
421 l11t1ljH{;lllll'I 46
422 H1•11ln11111lho luol llih r 46
4 23 1111, d111u'"t'11111ov 1..m . . ..... 49
4.3 Coollny •v• tt1,u 50
431 1>uu11inQtooh111ttuul llllinq syslmn with coolant 50
432 <.10:11111,g1111cooll11qhmt hotttingsystems 51
433 V 111111 51
44 C.lulc
h 53
4 4 1 Hyth ult• aoc11ons01 c1u1,h and brake
flV!I IPII I , '"" ku1u llutd lovol .' ........ 53
4.5 To111•ml11lun .. .. .... 54
451 M11 u, ,, 111•,1111111011 .. .... .. 54
4 5 1 1 011hwol chm. k tout 011 t.:h,rngo ... .... ... 54
4512 Cl11u11111uIJroutrw, 54
452 MlI trnlOUl•lliC lri,trl:UrnS510fl 54
4521 011tovl'i c""' k 55
4522 0,1 HIIII flllPI <hanqn 55

Page
43
45
45
46
47
47
48
48
48
49
50
50
51
51
53
53
54
54
54
54
54
55
55
4 II
4 ,
•17 I
,1 ( 'l.
,1 7 3
" ( ·1
4 II
481
48?
,1 11
,1.112
~,'I 3
410
·1 10 1
., 10 7
4 103
1104
·I 105
4 11
Rear axle
OIi level check and oil change
Steering
Checking the steering linkage
Checking steering free play ..
Checking oil level
Checking the toe-in
Wheels and tires
Spare wheel locat ion
Wheel change
Brake system
Checking the brake lines .
Checking brake lining thickness
Hydraulic sections of clu tch and brake
systems - checking fluid level
Bleeding the brake system
Electrical system
Three-phase alternator
Fuses
Checking the headlighl alignmenl .
Headlight bulb replacement
Battery care . . .... ... .... ... ..•. .
Vehicle cleaning and care
Pago
57
57
58
58
58
59
59
60
60
61
62
62
62
64
65
66
66
66
68
68
69
70
4.1:1 Preparing the vehicle for storage .
4,13 Preparing the vehicle for service after storage
~ Troubleshooting
,, 1
~;>
53
!J4
5 !>
56
5 7
58
Engine and fuel system ... .... . . .
Clutch.
Steering
Brake system .
Electrica l system
Supp lementary heater .
Shutt ing off the engine when the vacuum system is faulty
Tow-starting and towing the vehicle . ....... .
6 Technical data .
6 1
62
63
64
65
6 6
67
68
69
610
6.11
612
Data cards/identifica1 ion plates
Weights
Main dimensions
Engine ..... . ... ... .
Cooling system
Clutch .
Transmiss ion . ___ .. . .. . _
Steering system
Front axle ..
Rear axle .
Brake system ..
Electrical system ....... •. . . . .... ....... .. .
7 Tightening torques ..... ..... . . .. . .. . ....... . . . .... . .
8 Capacities - summary
9 Service and maintenance jobs - summary
Tire pressure chart
Page
71
72
73
73
74
75
76
77
78
79
80
82
82
84
84
85
86
86
86
87
87
88
89
90
97
98
100
5

1 Components
6
1.1 Door control front
Hinged door
Doorcontrol, outside
1 Locked
2 Unlocked
Toopen the door,
press in door lock cylinder
Door and window control, inside
1 Door latch unlocked
2 Door latch locked
3 Opening lever,door
<1 Window crank

I 'J Driver's seat adjustment
•,I,111dordversion
Itcight of seat, front portion
,' I orward and rearward
Itc,ght of seat, rear portion
,1 Scat back
Make Bremshey
1 Seat load
2 Seat load scale
3 Height of seat,front and rear
4 Seat back
5 Forward and rearward
6 Seat lock
Lever moved to tho right = locked
Lever moved to tho left = released
1.3 Seat belt (example)
Fastening:
1. Pull belt with tongue (1)over shoulder
and lap. The belt must not be twisted
but must be tight.
2. Press tongue (1) into buckle (2) and
allow to engage audibly.
Unfastening:
1. Depress red button in buckle (3).
2. Return tongue (1)to initial position.
Note:
The inertia reel of the seat belt stops the
belt unwinding further in case of vehicle
deceleration inany direction and ifthe belt
is pulled out quickly.
7

l
1.4 Instruments - summary
8
Ventilation and defrost ing nozzles for side windows
(page 16)
2 Light switch (page 12)
3 Coolant temperature gauge
4 Indicator lights (page 10)
5 Speedometer or tachograph (page 13)
6 Selector lever position indicator - MB automatic trans-
mission or fuel gauge (page 31)
7 Idle speed control (page 29)
8 Switches (page 10)
9 Heating and ventilation (page 16)
10 Plug socke t
11 Rmho (page 14)
12 Ashtmy
13 E11g1nocover
14 Clock
15 Stec,1ng lock (page 13)
16 Horn
17 Fuol gaugo or operat ing hours indicator
18 Co111ti111i1l1on switch (page 12)
19 Pull knot,, engine compartment flap (page 23)

9

L
1.5 Indicator lights and switches
The following symbols have been chosen to facilitate identification of tht> 111ct1v1ch1.il•,wile11,,,,.111cl1ndicator lights.
Indicator lights
High bea m
2 Preglowing
3 Turn signal indicator light - tractor
4 Turn signal indicator light - trailer
5 Rotary flas hing beacon
Switches
11 Blowe r, hig h speed - low speed (page 16)
12 Heated rear window
13 Rotary flashing beaco n
14 Interior light - bus
10
6 Cl1i111w l11dh,,tm hqhl (page 36)
7 Brnk1•lh11ct,11Hll>ruko pad wear (page 34)
8 011JIIIH,'11111'lll191n0
9 Il<'dl«'cl 1<'111WlllCIOW
10 Supph11111111t111yheater (page 16)
15 Supp lt>11H•11t,11yheater (page 16)
16 Haz,ucl wi1111111qfl,1sher switch with indicator light
17 Light •,w1tc11(pogo 12)

11

1 1.6 Light switch
0 Off-position
1 Parking lights
2 Headlights
3 Standing lights, right
4 Standing lights, left
A As position 1 or 2 plus fog lights
B As position 1 or 2 plus rear fog light
with indicator light
12
1.7 Combination switch
1 Low beam
2 High beam
3 Headlight flasher
4 Turn signal lights, right
5 Turn signal lights ,left
Note:
Switch ing on turn signal lights
Up to point of resistance= bnef fln~.11111q
Beyond point of resistance (engagmwnl)
= cont inuous flashing
li Windshield washer/head light washer
Noto: When the windshield washer sys-
h•m1sactuated,the windshield wipers are
r1lsoswitched on.
1110 headlight washer (optional) is only
orwrated when the vehicle lights are
,;witched on.
Check wiper blades regularly for soiling
r1mt ctnmage.
7 Windshield wiper
Position "O"= off
Position "I"= intermittent wiping
Position "II"= low speed
Position "Ill" = high speed

0
;;;
0
"'
(!)
1sher
· sys-
rsare
only
; are
:,iling
I It looring lock
II Iht>key can be removed only in this
pos1llon.
Iho steering is locked when the key is
w1lhclrawn.
•,It•t'rtng unlocked
I'tt'q lowing and driving position
•,I,11t1ngposition
1.9 Tachograph (uxiunp lo)
1 Time group knoll
2 Speedomet er
3 Speed warning ltqht
4 Clock function control light
5 Tachograph funcllon control light
The control light comes on if no dia-
gram chart is inserted or if the tacho-
graph is defect1vo.
Brief lighting up of the control light
while the tachog raph is opened or
closed proves the control light to be in
good working ardor
13

I
j1
I
I
1.10 Radio
Radiowith push buttons for band selection andtuning of preset
stations
Radiowith push buttons for band selection and tuning of preset
stations and with built-in cassette player
14
1 On-Off/Volume control
2 Tone control
3 Push buttons for band selcctton and tuning of preset sta-
tions
4 Manual tuning control
5 Cassette release
6 rast forwnrcl
7 Fast rt•wind
8 Ca'iSollt' slot
9 Wavo llancJ111ellc.itor

,et sta-
1111I 1111Voh11nl' con trol
111111k1111ll(1) clockw ise to switch on radio and to incr ease
v11h11111•Iho qreen co ntrol light will come on.
1111111
ll1111l11v,.,
(2) to alter the tone .
111111111l11111ng
1 1111Ich•s1redwave band by pushing the respective button (3).
I111w11v11l>andselected is indicated by wave band indicator (9)
1111cl11!,lll!dstatio n is tuned in by turn ing the manual tuning
~11f1lo
(4) f or good reception, accurate manual tuning is impor-
t 1111
1111111•·,nlstations of various wave bands pull out preset button
( II 1111111•stop, tune in station with manual tuning knob (4) and
1111
.i, prnsct butto n in again to the stop.
I 1111,I1i,1yback
f 1111v 11•,1•brand C 60 or C 90 cassettes. Push cassette into
l fl ,1•111•slot as far as it will go with the full reel on the right side.
Ilw radiowill then switch over from radio recep tion to tape play-
Iiack. Thecassette will be released auto maticall yas soon as the
lapo reaches its end.
Io piny the other side ofthe tape, turn casse tte upside down and
101nscrtit into cassette slot.
lo manua lly eject the cassette, push release bar (5).When the
c.issette is ejected, the unit will switch over to radio recep tion
11ulomat ically .
I'ush button 6 or 7for fast forward or rewind of the tape. Briefly
touching the counteracting button wil l stop the winding pro-
cess.
Service and Maintenance
Since deposi ts on the pick-up head are inevitable after extend -
ed operation, the cassette shou ld be cleaned wit h a cleaning
cassette if the qua lity of the sound rep roduc tion dec lines.After
approx. 500 operating hours the unit should be inspected by a
special ist.
15

1.11 Heating and ventilation
Control levers are infinitely variable
Blower switch: press upper end
center position
press lower end
= low speed
=off
= high speed
2 Ventilating or defrosting windshield
Lever position : left = closed
right = open
3 Contro l valve for heater
Lever position: left - cold
right =warm
4 Ventilating or heating footwell
Lever position: left = closed
right - open
5 Supplementary heater
switch: press upper end - on
press lower end = off
6 Ventilation and defrosting nozzles - windshield
7 Ventilation and heating nozzles - footwell
8 Ventilation and defrosting nozzles, adjustable
The nozzles can be opened and close d with the lever
in the nozzles.
Supplementary heater
The supp lementary heater can be operated with the engine on
or off.
Switching on supplementary heater:
Actuate toggle switch. The indicator light on the instrument
panel comes on. The heater will come on after approx.
2 minutes.
16
Adjusting examples:
When defrosting windows
1 - press lowerend
2 right
3 right
4 - left
8 - turn nozzles towards side window and
open them
For full heating capacity
1= press lower end
2 right
3 nght
4 - right
Forfull ventllal1011
1 - press lowl'r encl
2 - nght
3 = left
4 = right
Switching off supplementary heater:
Actuate toggle switch.The indicator light goes out. The heater
continues to operate for about 2 minutes and then switch es off
automatically.

,eater
1esoff
17

1.12 Headlight beam control
.·.·--.·.·+·· ·fa#%· .... ··<·)y} {&&::
0 Normal position
I Vehicle with maximum load
(with evenly spread load)
Vehicle with maximum load
18
(with large part of load shifted to rear
axle)
1.13 Interior light (examp le)
Position 1: On
Position 2: Off
Position 3: Light is switched on ,IIH I oll
by the door contact
1.14 Interior mirror
2~1
Operating lever
1 Normal position
:> Dimming position

t I nnt lock - assistant driver's seat
Ilt1locking right
r >porate lever, tilt seat forward or
l>ilc:kward until lock engages.
Unlockin g left
Operate lever,tilt seal forward or back-
ward until lock engages.
19