Mercedes-Benz 410 D User manual

Operating Instructions

® Mercedes-Benz
Operating Instructions
208 D 210 D 210
308 D 310 D 310
408 D 410 D 410

2
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 determ ined 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 official 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 1nthe data and illustrations of these
Operating Instructions (s.e.e.o.).
Reprinting, translation and copying, even of excerpts, 1snot permitted without our prior
authorization 1nwnttng.
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
3

Contents
Data car ds/identification 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 ............... .
2.1
O Headlight beam control . ........ . .. .
2.11 Interior light ..................... .
2.12 Interior mirror ................... .
2.13 Seat lock - assis tant driver's seat
2.14 Headrest ........... . ... . ....... .
2.15 Seat heater ............. . ....... .
2.16 Heating and ventilation .... . .. . .... .
2.17 Supplementary heater .. . .......... .
2.18 Door control - cargo space ......... .
2. 19 Engine cove r ..... . .............. .
2.20 Engine compartment flap ... . .. . .... .
3 Operation ... . ............... . ... . . . .
3.1 Prepara tions 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 operation ................. .
4
Page
6
7
7
9
10
12
14
14
15
15
16
17
17
18
18
19
19
20
22
24
28
29
30
30
36
39
39
44
45
48
49
50
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 l ightening torques ... . ........... .
5.1.3 Oil and filter change .............. .
5.1.4 Renewal of air cleane r 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, cleani ng . .
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 0 11level check and oil change ...... .
5.5.1.3 Cleaning breather .. ... .......... .
5.5.2 MB automatic transmission ......... .
5.5.2.1 Tighten ing torques ............ . .. .
Page
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61
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70

1e
i2
i2
i3
i4
i7
,9
;o
;1
;1
;3
;3
;5
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i8
i8
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;9
'O
'1
'1
'1
'1
'2
'O
'O
!.>.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
Rear axle ......... . .......... .
Tightening torques .............. .
0 11level 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 ................ .
5.11.3 Fuses ....................... .
5.11.3.1Testing fuses .. . ............... .
5.11.4 Battery care ................... .
5.11.5 Checking the headlight setting
Page
72
73
74
74
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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
Headlight bulb replacement ....... .
Three-phase alternator .... . ..... .
Visual inspec tion of spark plugs
Bulbs - summary . . ... . ......... .
Wmng diagrams ....... . ..... . .. .
5.12 Chassis and body ..... . ........ .
5.12.1 Inspec tion and maintenance of trailer
coupling ...................... .
5.12.2 Ad1ustment of side board locks ..... .
5.12.3 Lubrica tion .................... .
5.13 Vehicle cleaning and care
5.14 Preparing the vehicle for storage
5.15 Preparing the vehicle for service
after storage .................. .
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
vacuum system is faulty .......... .
6.9 Fan with fluid coupling ........... .
6.1O Tow-starting and towing the vehicle
Tire pressure chart
Page
83
84
84
85
86
103
103
103
103
104
105
106
107
107
109
110
111
112
113
114
114
115
116
5

6
Body number , paint code no on
left side front cab post
1 Data cards/identification plates
With the vehicle you are handed over data cards listing all the important vehic le
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.
Card no. 1
For safety reasons this 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)
7

8
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
9

1 Tongue
2 Bucl<le
3 Button
10
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
it
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.
11

2.4 Instruments and controls
'{ 21
Vent1lat1onand 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 14)
6 Selector lever pos1t1onindicato r - MB automat ic
transmission (page 41) or fuel gauge
7 Choke control 210, 310, 410 (page 37)
8 Switches
9 I lea1ing and ventilation (page 20)
1:>
10 Plug socket
11 Glove box
L
-.....,_"\\
11
12
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)

~
Iliyh beam
Iii] Interior light - bus
~
D1fferent1al lock, rear axle (page 42)
RU
Choke control (page 37)
filij Preglowing (page 36)
5-Xi
Turn signal indicator light - tractor
5-Xi
Turn signal indicator light - trailer
B Rotary flashing beacon
Ill Step
~witches
Blower (page 20)
Heated rear window
Rotary flashing beacon
Seat l1eater (page 19)
D ABS (page 48)
•Dump body
lrn
Shift lock power take-off, (page 43)
Iii Charge indicator light (page 46)
~
Brake fluid and brake pad wear (page 46)
m
Oil pressure - engine
t?J
Heated rear window
•Supplementary heater - operat ion indicator light
(page 22)
[ii.]Interior light - bus
laDump body
MHazard warning flasher system with indicator light
mSupplementary heater (page 22)
13

14
2.5 Tachograph (example)
1 Time group knob
2 Speedomete r
3 Speed warning light
4 Clock function control light
5 Function control 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 1swithdrawn, 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
~ A Fog lights on in position 1 or 2
"'
c, B Fog lights plus rear fog light with indicator light on in positio n 1 or 2
15

"
16
2.9 Combination switch
Low beam
2 High beam
3 Headlight flasher
4 Turn signal lights, right
Up to point of resistance = brief flashing.
Beyond point of resistance (engagement) = continuous flashing.
5 Turn signal lights, left
Up to point of res istance = brief flashing.
Beyond point of resistance (engagement) = continuous flashing.
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 (optio nal) is only
operated when the vehicle lights are switched on.
Check wiper blades regula rly for soiling and damage.

ly
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.
17

18
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 .

I
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;;;.:::::::::;,::::'.•:-//::::,
2.14 Headrest (example)
Height and inclination of headre st can be adjusted.
2.15 Seat heater
Control switch
Press upper end (II) = fast heating
Center position = switched off
Press lower end (I) = continuous operation
If the engine is off, do not engage po~ition ,,fast heating" for longer than is
abso lutely necessary.
19