In an Emergency

Hazard Warning Lights

The hazard warning light switch tab is located on the turn signal control lever. See Fig. 21.1 . To operate the hazard lights, pull the tab out. All of the turn signal lights and both of the indicator lights on the control panel will flash.

Fig. 21.1, Hazard Warning Light Switch Tab

To cancel the hazard warning lights, push the turn signal control lever either up or down, then return the lever to its neutral position.

Fire Extinguisher

A fire extinguisher is located either in the cab by the driver's door, or in the baggage compartment.

Emergency Kit, Optional

An optional emergency kit may be located in the cab. The package includes one or more of each of the following: first aid kit, a reflective vest, and a triangular reflector and flare kit.

If there is an emergency while driving, cautiously pull off the road, paying attention to other traffic. Turn on the hazard warning lights. Place the flares and reflector along the side of the road, to alert other drivers that an emergency situation exists.

Use extreme care when placing flares in emergency situations that involve exposure to flammable substances such as fuel. An explosion or fire could occur causing serious personal injury.

Emergency Filter Replacement, DAVCO

If the filter cover on the DAVCO fuel/water separator is broken, it will not be possible to operate the vehicle. A standard spin-on filter will correct this problem.

Refer to the DAVCO web site for additional information,www.davcotec.com.

Fluid circulated through the fuel/water separator to heat the fuel may be diesel fuel returned from the engine, or engine coolant. Drain the fuel/water separator only when the engine and fluids have cooled. Draining it when the engine is hot could cause severe personal injury due to scalding.

If returning fuel is released into the atmosphere, its vapors can ignite in the presence of any ignition source. Do not expose the fuel to, or work with the fuel system near, open flame or intense heat. To do so could cause fire, possibly resulting in serious personal injury or property damage.

Shut down the engine, apply the parking brake, and chock the tires.

Put a clean receptacle under the fuel/water separator and attach a piece of hose to the drain valve, to direct fuel into the receptacle.

NOTE: The drain valve on the Fuel Pro 382 has a 1/2-inch (12.7-mm) opening; use a hose with a 1/2-inch pipe thread to fit correctly.

Remove the vent cap ( Fig. 21.2 , Item 14) and open the drain valve ( Fig. 21.2 , Item 1) to drain the fuel to just below the collar level, then close the drain valve.

1. Drain Valve
2. Bottom Plate
3. Heat Exchanger
4. Bottom Plate O-Ring
5. Lower Housing
6. Grommet
7. Cover O-Ring
8. Inlet Port/Check Valve
9. Fuel Outlet Port
10. Filter Element
11. Spring
12. Clear Cover
13. Vent Cap O-Ring
14. Vent Cap
15. Collar

Fig. 21.2, DAVCO Fuel/Water Separator (Fuel Pro 382 shown)

Using a DAVCO collar wrench ( Fig. 21.3 ), remove the clear cover and collar.

Fig. 21.3, DAVCO Collar Wrench

NOTE: Broken vent cap and collar warranty claims will not be accepted if any tool other than a DAVCO collar wrench, p/n 380134 or 382002, is used for removal. During installation, the vent cap and collar are to be hand-tightened only , not tightened with a wrench.

Remove the filter and dispose of it in an environmentally acceptable manner.

Clean all threads and sealing surfaces very thoroughly. Even a small amount of dirt will prevent the fuel/water separator from sealing, and an air leak will result.

Ensure that the drain valve is closed.

Remove the filter grommet from the filter stud, if equipped.

Fill the housing to the top with clean diesel fuel.

10.

Install a standard fuel filter element on the filter stud. If a standard filter element is not available, install a spin-on fuel filter element (part number FF105 or equivalent).

11.

Install the cover O-ring, clear cover, and the collar. Hand-tighten the collar.

12.

Install and hand-tighten the vent cap O-ring and vent cap.

13.

Start the engine. When the lubricating oil reaches its normal operating pressure, increase engine speed to high idle for one to two minutes to purge air from the system.

Emergency Starting With Jumper Cables

When using jumper cables, follow the instructions below.

Batteries release explosive gas. Do not smoke when working around batteries. Put out all flames and remove all sources of sparks or intense heat in the vicinity of the battery. Do not allow the vehicles to touch each other. Do not lean over the batteries when making connections, and keep all other persons away from the batteries. Failure to follow these precautions could lead to severe personal injury as a result of an explosion or acid burns.

NOTICE

Make sure both electrical systems are the same voltage. Electronic devices on both vehicles can be damaged when connected to a vehicle with a different operating voltage.

Apply the parking brakes and turn off all lights and other electrical devices. Ensure that the vehicles are not touching and both ignition switches are turned to the OFF position.

IMPORTANT: Do not attempt to jump start a damaged battery.

Remove the battery box cover.

NOTICE

Always connect the batteries and jumper cables correctly (positive-to-positive and negative-to-negative). Connecting a charging device backwards (positive-to-negative) can severely damage the vehicle electrical content and cause non-warrantable failures.

IMPORTANT: On vehicles equipped with optional jump start posts, connect to these posts instead of the battery terminals. Jump start posts may be installed in various locations on the vehicle.

Connect the positive (+) jumper cable to the positive battery terminal or jump start post. See Fig. 21.4 .

Disconnect jumper cables in the REVERSE order that they were connected.

A. Discharged Battery
B. Negative Ground Stud
C. Positive Jumper Cable
D. Negative Jumper Cable
E. Booster Battery

1. 1st Connection
2. 2nd Connection
3. 3rd Connection
4. 4th Connection

Fig. 21.4, Jumper Connections

Connect the other end of the positive jumper cable to the positive terminal or jump start post on the booster battery providing the charge.

Do the next step exactly as instructed and do not allow the clamps of one cable to touch the clamps of the other cable. Otherwise, a spark could occur near a battery, possibly resulting in severe personal injury from explosion or acid burns.

Connect the negative (-) jumper cable to the negative terminal or jump start post on the booster battery.

Connect the other end of the negative jumper cable to the negative ground stud on the vehicle requiring the jump start.

Start the engine of the vehicle providing the jump start and let the engine run a few minutes to charge the batteries of the other vehicle.

Attempt to start the engine of the vehicle receiving the jump. Do not operate the starter longer than 30 seconds, and wait at least two minutes between starting attempts to allow the starter to cool.

When the engine starts, let it idle a few minutes.

10.

Disconnect the negative jumper cable from the negative cable stud on the jump started vehicle.

11.

Disconnect the negative jumper cable from the booster battery.

12.

Disconnect the positive cable from the booster battery.

13.

Disconnect the other end of the positive jumper cable from the jump started vehicle.

14.

Install the battery box cover; be sure it is positioned properly before fastening the latch.

Towing

NOTE: The vehicle shown in the figures is for reference only and may not match the model of your vehicle.

Shutdown the engine and set the parking brake.

Open the hood. Remove the tow hooks, located behind the driver's-side bumper. See Fig. 21.5 . Close and latch the hood.

NOTICE

New or ungreased tow hooks may be hard to install. Tow hooks that are not properly installed may be damaged or break.

Install the tow hooks onto the tow hook receivers through the tow hook holes in the bumper, rotating the hooks so the hook opening faces down. See Fig. 21.6 . Pull the tow hooks to ensure they are securely engaged in the tow hook receivers.

Fig. 21.5, Tow Hooks

Fig. 21.6, Tow Hooks Installed, Facing Down

Lower the stinger assembly so that it is level and approximately 1 inch (0.3 cm) off the ground. Back the tow truck so that the crossbar with lift adaptors is within 6 inches (15 cm) of the Aero bumper. See Fig. 21.7 .

Fig. 21.7, Positioning the Stinger Assembly

NOTICE

When using tow hooks to move the vehicle, do not pass a sling (for example, a rope or chain) from one hook to another. Known as reeving, this practice is not permissible in most industrial applications of towing and hoisting. Reeving can overload the hooks and result in damage to the vehicle. See Fig. 21.8 .

Pull the tow cables out of the tow truck and connect the tow cable lifting hooks onto the tow hooks, then extend the recovery boom within 4 to 6 inches (10 to 15 cm) of being vertical of the tow hooks. See Fig. 21.9 .

IMPORTANT: Do not reeve when towing.

1. Tow Hook
2. Chain

Fig. 21.8, Reeving

Lift the front of the vehicle until there is enough clearance for the stinger and crossbar to pass under the bumper. See Fig. 21.10 .

If enough clearance can not be gained with a single lift, jack stands or other means capable of supporting the weight on the front axle must be used while the cables are shortened to allow a second lift.

Fig. 21.9, Tow Cables Connected to the Tow Hooks

Fig. 21.10, Moving the Stinger and Crossbar Under the Bumper

Failure to chock the tires or connect the tow truck's air brake system before releasing the spring parking brakes could allow the disabled vehicle to suddenly roll. This could cause property damage or personal injury.

Chock the rear tires.

NOTICE

Reference the applicable axle manufacturer's information to avoid damaging the axle when towing the truck.

Use mid-rise or high-rise forks, or lift adaptors (part number 0200020) on the crossbar to provide clearance for the aerodynamic bumper. See Fig. 21.11 and Fig. 21.12 .

Fig. 21.11, Lift Adaptors Installed on the Crossbar

Fig. 21.12, Backing the Tow Truck with Lift Adaptors on the Crossbar

Extend the stinger and place the lift adaptors under the axle. Make certain the lift adaptors are under the front suspension springs between the U-bolts. See Fig. 21.13 and Fig. 21.14 .

Fig. 21.13, Positioning the Stinger with Lift Adaptors Under the Axle

Fig. 21.14, Stinger with Lift Adaptors Under the Axle (tow truck shown)

10.

Secure the axle to the crossbar with a chain or ratchet strap.

NOTICE

Failure to remove the driveline(s) or the drive axle shafts when towing the vehicle with the rear wheels on the ground could result in damage to the transmission and other parts.

11.

Remove all drivelines or all axle shafts for towing.

12.

Remove the tow cables from the tow hooks and retract the recovery boom. See Fig. 21.15 .

13.

Remove the tow hooks from the bumper.

14.

Connect the air and electrical supply lines from the tow truck to the vehicle being towed.

IMPORTANT: On vehicles equipped with a front air suspension, either air pressure must be supplied to the secondary air system or the front suspension must be blocked to operating height with wooden spacers and the axle chained to the frame to prevent damage to the vehicle.

15.

Release the park brake and remove the chocks from the rear tires.

16.

Use the stinger to pull the vehicle close to the back of the tow truck for final towing position. See Fig. 21.16 .

Fig. 21.15, Retracting the Recovery Boom

Fig. 21.16, Final Towing Position

17.

Connect the safety chains. See Fig. 21.17 .

Fig. 21.17, Safety Chains Connected on the Towed Vehicle

Fire in the Cab

The incidence of fire in heavy- and medium-duty trucks is rare. Federal regulations limit the flammability of specified materials used inside the cab, but despite this, most materials will burn. The cab of this vehicle contains urethane foam, which is of concern in this respect.

Do not allow flames, sparks, or any other heat sources (such as cigarettes or light bulbs) to contact materials in the cab. Any materials in the cab in contact with these heat sources could cause serious personal injury or vehicle damage.

In Case of a Cab Fire

As quickly as possible, bring the vehicle to a safe stop, apply the parking brake, turn off the ignition, and get out of the vehicle.