2003 LSSV Military Trucks Owner`s Manual Supplement
Contents
1. This adapter is located in the vehicle glove compartment NOTES 4 13 Section 5 Checking Things Under The Hood 5 2 Engine Compartment Overview 5 2 Jump Starting sper DR DG Yd 5 3 Vent FilterS oo 5 10 Rear Axle Vent Tube Filter 5 10 Transfer Case Vent Tube Filter 5 10 Front Axle Vent Tube Filter 5 10 Service and Appearance Care Replacement Bulbs 5 11 TIES oo ost een eve DO WALI 5 11 Changinga Flat 5 11 Inflation Tire Pressure 5 12 Appearance Care 5 12 Cleaning The Outside of Your Vehicle 5 12 Vehicle Information 5 13 Shipping Data Plate 5 13 Government Vehicle Data Plate 5 13 Electrical System 5 14 Fuses and Circuit Breakers 5 14 5 1 Checking Things Under The Hood Engine Component Overview e 0 p HT J j C 7ow X A g LU ATE NN WW UU NW A WY we ty IE The following items are military options that may be found on the vehicle A 24 Volt Generator C Circuit Breakers E 24 Volt Battery B 24 Volt Generator Circuit Breakers D 24 Volt Relay 5 2 Jump Starting If the battery or batteries on the vehicle have run down and the vehicle will not start you may want to use another vehicle t2. N 2 Turn off the ignition on both vehicles Unplug unnecessary accessories plugged into the A CAUTION cigarette lighter or accessory power outlets Turn off all lamps that aren t needed as well as radios Using a open flame near a battery can cause This will avoid sparks and help save both battery gas to explode People have been hurt batteries In addition it could save your radio doing this and some have been blinded Use a E flashlight if you need more light Notice If you leave your communications navigation eguipment on they could be badly Be sure the batteries have enough water You damaged The repairs will not be covered by don t need to add water to the Delco Freedom battery or batteries installed in every new GM vehicle But if a battery has filler caps be sure the right amount of fluid is there If it is low add water to take care of that first If you do not explosive gas could be present your warranty Battery fluid contains acid that can burn you Do not get it on you If you accidentally get it in your eyes or on your skin flush the place with water and get medical help immediately 3 Locate the slave receptacles on both vehicles and Fans or other moving engine parts can injure unscrew the cover you badly Keep your hands away from moving parts once the engine is running 4 Connect the slave cable to the vehicle with the dead battery 5 Start the vehicle with the good battery 6 C
3. Cab 17 Lower Weapon Holder csi 17 Upper Weapon a RR 17 Section3 Instrument Panel 19 Blackout Drive Light e 21
4. Rear Window Door XX121 nennen nnne nnn nnne nnn 10 WI GW me 10 Rear Topper WIN IOWA UO 10 Closing the Side Window Doors 9 99999 2 Y YY LLLLLLLLLLL onn ren nnnnn cnc nnrr nnn nnn 10 Side Topper sigo RP DA nani 10 Open the Side Window DOOIS 5 neon eran nitur KNANG LANGAN Sung a EY EFE E RNA MAR 10 Closing the Rear Wir mec 11 Sliding Rear Window 2 ssccscsenesnnncececcneeseesennnnnneneneeeeeneeseeeennnsnaneeeeeeaeeeenenens 11 Opening the Rear Window Lueeeeeeeeeeeeeeeeee eene nennen nnn nnn n nnn nnne nennen nennen 11 alli use eripe X X 11 kC Vehicle A eee AA PAP 11 Starting Your ENG DM 11 Fuel Fired Coolant Heater 228mm Aa 12 Fuel Fired Coolant Heater Operation eese 12 Rolling Up Ihe Side Panglima 13 SIOrage ANGAS m 13 Cargo Cover Soft Top If EQquipped oooooococccccccncnnnnnnccncccnnnnnononnnnnnnnnnncnnnnnnnnnnnnnnnnnas 13 Storing the Cargo Cover nue uii RA RWY n 13 Cargo Tie Downs If Equipped unione NN Kk raduno diaria ann 15 Weapons MOUM gue M 16 Floor Mount Weapon Mount Crew Cab suus 16 Mounting the Weapon ununi nitri niani n RR iia 16 Behind Seat Weapon Mount Standard
5. a DA 5 10 Rear Axle Vent Tube Filter 5 10 Transfer Case Vent Tube Filter 5 10 Front Axle Vent Tube Filter 5 10 Warning Lights Gages and Indicators 3 8 24 Volt Voltmeter Y Y eee 3 8 Weapons Mount Y Yg 2 8 Floor Mount Weapons Mount 2 8 Behind Seat Weapons Mount 2 9 Weight of the Trailer lt 4 9 Winch Accessory Kit 4 5 WING PF ED 4 3 Winch Storage Y YY YR ee 4 3 Multi Mount cocino 244 500 mmm a 4 3 Control Of Your Winch d 4 5 How the Winch Reacts to Load 4 5 WIDOOWS 2a nea sata AGANE toe Y RFC DUE BD 2 2 Rear Topper Window Yu 2 2 Side Topper Window Yu 2 2 Your Driving The Road and Your Vehicle 4 2 Loading Your Vehicl6 Y 4 2 8 3 Contents Section 1 Seats and Restraints eeeeesesesss 4 Troop Seat OPC HUI me 5 Folding the Seal DOWN RR 5 Troop Seats If Equipped een 5 Folding the Seat UD Mau ANCR aM GAA RNAN 6 PACS EE HMO aa 7 Rear Salely Strap AA 7 Section 2 Features and Controls 9 Closing Rear Window DOOF used ru ien olera i eol ink x ERE a 10 Opening the
6. can handles These could cause you to lose carry up to eight passengers Passengers must stay control Also overloading can shorten the life seated at all times of your vehicle Notice Your warranty does not cover parts or components that fail because of overloading 4 2 Winch If Eguipped Multi Mount The multi mount winch has 9 000 lbs 4 082 kg of single line pull The multi mount slides into the hitch receiver and allows you to move and operate the winch from the front or the back of vehicle Refer to WARN industries operator s manual in the vehicle glove compartment for additional instructions and warnings 4 3 Multi Mount Winch Storage NA O NN I ig p au A es The multi mount winch is stored in a locking storage box located in the upper middle of the cargo area The winch is secured in the box by four floor mounted eye bolts Permanent Mount ES PS hl Lt A mmf The winch is electrically powered from the vehicle batteries The permanent mount winch has 12 000 lbs 5 440 kg of single line pull Refer to WARN industries operators manual in the vehicle glove compartment for additional instructions and warnings Control Of Your Winch The winch is controlled by the hand held remote control to allow the operator to stand clear while controlling the winching process The remote control provides control of the forward or reverse rotation of the spooling drum The w
7. leg for down positions passenger s side seats or a right hand leg for drivers side seats It will then go through the seat channel and will be placed in front of the Troop Seat Operation hinge pin Folding the Seat Down Remove the pin and place the legs into the joint of the truck side and the truck floor 4 Place the pin in the hole provided under the hinge pin 5 The seat is now locked in the down position Folding the Seat Up Reverse Steps 1 through 5 To remove the troop seats refer to Seats in the 2003 LSSV Military Trucks service manual supplement Restraints Rear Safety Strap y a Whenever the troop seats are occupied the safety strap should be attached across the top of the rear seat backs using the eye bolts provided NOTES Section2 Features and Controls Windows 2 2 2 Storage Areas 25 Rear Topper Window 22 Cargo Cover Soft Top 2 5 Side Topper Window 22 Cargo Tie Downs 2 7 Sliding Rear Window 2 3 Weapons Mount 2 8 Starting and Operating Your Vehicle 2 3 Floor Mount Weapons Mount 2 8 Starting Your Engine 2 3 Behind Seat Weapons Mount 2 9 Fuel Fired Coolant Heater 2 4 2 1 Windows Rear Topper Window Opening the Rear Window Door 1 Turn both handles A cl
8. of force Always pull the vehicle straight out Never pull on the clevises at a sideways angle The clevises could break off and people could be injured from the chain or cable snapping back When recovering the vehicle you should determine the direction of the recovery by the distance required to free the vehicle and the surrounding terrain Secure the towing cable to both front or rear clevises with a V device to gain an even pull on both anchor points and avoid damage to the vehicle Front Clevis Towing Provisions Rear Clevis Towing Provisions Factory Bumper 4 6 Maximum Allowable Loads on Each Clevis Towing Shackle Regular Cab Models Military Bumper ar i RR RR C NR Rearward Rear Ol Upward Front 10 000 lbs 4535kg rn upward Rear DownFront 10 000 Ibs 4 535 kg Down Rear E Crewcab Models Military Bumper a OA ER Rearward Rear_ o d NN Upward Front O MA 10 000lbs 4535kg p Upward Rear Down Front 10 000 bs 4535 kg Down Rear o o 4 7 Towing Towing Your Vehicle When towing the vehicle you should always use a properly equipped wrecker recovery vehicle Refer to Towing Your Vehicle and Recreational Vehicle Towing in the Index of the 2003 C K Truck Owner s Manual for further information on towing the vehicle Notice The steering wheel must be secured properly with the appropriate wheel locking device to keep the wheel in the straight
9. position The vehicle transfer case must be in NEUTRAL N Towing a Trailer Your vehicle is eguipped for towing a trailer Notice Do not exceed the maximum allowable weight your vehicle is designed to carry Exceed ing the maximum allowable weight may cause damage to your vehicle Refer to Towing a Trailer in the Index of the 2003 C K Truck Owner s Manual for more information on trailer towing Your vehicle is eguipped with a pintle hitch for towing a trailer You must not exceed the maximum trailer weight towing capacity for that vehicle Refer to the following chart to find the maximum trailer weight for your vehicle 4 8 Weight of the Trailer Maximum Trailer Weighi GOWA Factoy Regular Cab Model Military PT Faetow Y Crew Cab Model The Gross Combination Weight Rating GCWR is the total allowable weight of the completely loaded vehicle and trailer including any passengers cargo equipment and conversion The GCRW for your vehicle should not be exceeded Towing capacity is limited by the military hitch not vehicle performance Towing capacity must be reduced when trailer towing is used in ON OFF road conditions Pintle Hitch A pintle hitch is located at the rear of the vehicle and is removable from the receiver Operating the Pintle Hitch 1 Rotate the hitch so that the T handle faces upward 2 Remove the locking pin from the side of the hitch 3 Pull the T ha
10. the control lever pivot point and all exposed control linkage The transfer case is equipped with an in line filter on the vent tube Inspect the filter for blockages and replace as needed Inspect vent hose at the transmission and transfer case for kinks and proper installation Refer to Transfer Case Vent Tube Filter in the Index for further information on the location of the filter Refer to Maintenance Schedule in The 2003 C K Truck Owner s Manual for additional maintenance information on the vehicle 6 2 Fuel Fired Coolant Heater Inspection The heater reguires no periodic maintenance other than a visual inspectionby a gualified technician preferably prior to the cold weather use The technician can ensure the heater and all components are free from damage and in proper working condition During the warmer months of the year when heating is not reguired the heater should be switched ON and allowed to run for 5 to 10 minutes once a month as a minimum This will keep a clean fresh supply of fuel in the heater fuel system and keep all moving parts in top operating condition For troubleshooting information refer to 2003 LSSV Military Trucks Service Manual Supplement 6 3 Winch Inspection Inspect the wire rope before and after each winching operation f the wire rope has become kinked or frayed the wire rope needs to be replaced Be sure to also inspect the winch hook and hook pin for signs of wear or damage
11. 2003 General Motors LSSV Military Truck Owner Manual Supplement Seats and Restraints Systems 1 1 Driving Your Vehicle 4 1 A e Your Driving The Road and Your Vehicle 4 2 Restraints 0cccceccccceceeuee 1 4 MOWING sc dice care TIERS 4 8 Features and Controls 2 1 Service and Appearance 5 1 WINDOWS npa METRE PD 2 2 Checking Things Under the Hood 5 2 Starting and Operating Your Vehicle 2 3 Vent Filtets niece ret trama 5 10 Fuel Fired Coolant Heater 2 4 Replacement Bulbs 5 11 Storage Areas E ba BG NAN IA KAP a AA BAN FUN GA 2 5 Tires lu toa D AN Y a FR ada AH 5 1 1 CargoTie Downs lu 2 7 Appearance Care 5 12 Weapons Mount 0 5 2 8 Vehicle Information 5 13 Electrical Systems 5 14 Instrument Panel 3 1 Exterior Lamps ET eae eye es eek Boek ge eae a eee 3 2 Maintenance Schedule Aa o 6 1 Interior lampS8 songs ANAN LA a 3 6 Maintenance Schedule 6 2 Warning Lights Gages and Indicators 3 8 Customer Assistance Information 7 1 Customer Assistance Information 7 2 A Y eee a 8 1 This supplement contains information that Driving Your Vehicle i i f hicle Th Pons 15 ihe nperaion Af your VCH ka As with other vehicles of this type failure to operate sections in this supple
12. Engine Ground Dead Battery If this procedure does not work you will need to disconnect the 24 volt side battery and charge it alone for 10 minutes Replace the battery and repeat the jump starting procedures as outlined Note This procedure should only be performed by your maintenance section T Slave Starting N CAUTION Batteries can hurt you They can be dangerous because They contain acid that can burn you They contain gas that can explode or ignite They contain enough electricity to burn you If you do not follow these steps exactly some or all of these things can cause personal injury Notice Ignoring these steps could result in costly damage to your vehicle that wouldn t be covered by your vehicle warranty Trying to start your vehicle by pushing or pulling it will not work and it could damage your vehicle You should only use the NATO slave receptacle and slave cable when performing this operation 1 Get the vehicles close enough so the slave cable can reach but be sure the vehicles are not touching eachother If they are it could cause a ground connection causing your vehicle not to start and the bad grounding could damage the electrical systems To avoid the possibility of the vehicles rolling set the parking brake firmly on both vehicles involved in the jump start procedure Put the automatic transmission in PARK P Be sure the transfer case is in a drive gear and is NOT in NEUTRAL
13. Replace if necessary Inspect the remote control for damage if equipped Refer to the WARN industries operator s manual in the vehicles glove compartment for additional inspections and maintenance NOTES 6 4 Section 7 Customer Assistance Information EEU TI Nd TA rJ Customer Assistance Information 7 2 Contact Information 7 2 7 1 Customer Assistance Information Contact Information For customer assistance phone numbers refer to GM Customer Assistance Center general information dealer 1 800 263 3777 location other concerns Contact Information To assist in our review of your concerns provide the following information Roadside Assistance Center towing and all Roadside 1 800 268 6800 Assistance program services The Vehicle Identification Number This will be on the VIN plate in the cab of the vehcile Current mileage on the vehicle Mailing Address GM Defense Military Trucks MC 483 A19 A24 100 GM Renaissance Center P O Box 100 Detroit MI 48265 o Nature of the porblem 7 2 NOTES 7 3 Section 8 Index Appearance Cani otra na AGA LAS o 5 12 Cleaning the Soft Top Cargo Cover 5 12 Cleaning the Outside of the Vehicle 5 12 Biackout Drive Light o0 ooooooooooooo 3 2 Cargo Cover SoftT0p VY Y eee 2 5 Cargo TieDowns sels 2 7 Changing a Flat so ines nte RR Rd 5 11 Checking Things Und
14. S functional 1 Pull the switch outward then UP to the ON position the front blackout drive lamp will activate With the ignition switch in the ON position The vehicle s military 12 pin and commercial 8 pin trailer wiring connectors and trailer lamps are also 9 P 2 Pull the switch outward then DOWN to the OFF controlled by this switch d position the blackout drive lamp will deactivate 3 The switch will return to the center position automatically after you release it from either the ON or OFF position 3 3 Operating Service and Blackout Lighting Exterior Lamp or Device Headlamps and Taillamps Parking Lamps Front Rear Side Marker Lamps Marker Lamps Roof Fender and End Gate Stop Lamps Back Up Lamps License Plate Lamp Front Rear Turn Signals Hazard Warning Lamps Cargo Lamp If Eguipped Horn Front Rear Blackout Marker Lamps Blackout Stop Lamps Blackout Drive Lamp Headlamp 3 4 Service Lights Blackout Switch SERVICE ON SERVICE ON SERVICE ON SERVICE ON SERVICE ON SERVICE ON SERVICE ON SERVICE ON SERVICE ON SERVICE ON SERVICE ON BLACKOUT BLACKOUT BLACKOUT Blackout Drive Light Switch OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF ON OFF ON OFF ON Exterior Lamp or Device Service Lights Blackout Switch Blackout Drive Light Switch Instrument Panel Switch lllumination SERVICE ON OFF Radio Clock lllumination SERVICE ON OFF Headlamp High Beam Indicator SERVICE ON OFF Tur
15. amp 3 6 Operating Service and Blackout Lighting 3 4 Warning Lights Gages and Indicators 3 8 24 Volt Voltmeter 3 8 3 1 Exterior Lamps Service and Blackout Lighting BLACKOUT SERVICE DRIVE LIGHT ON LIGHTS p SI TD ON BLACKOUT OF Service Lights Blackout Control This switch located on the blackout switch panel next to the 24 volt voltmeter is the service lights blackout control With the Ignition Switch in the ON Position 1 Pull the switch outward then push upward to the service ON position All normal service lamps will be operational with normal controls 2 Move the service light blackout switch to the center OFF position All lamps and accessory power to the vehicle will turn off 3 Move the switch to the blackout position the Blackout Drive Light following will occur inhti The switch located on the blackout switch panel next e The blackout lighting system will be operative dua to the service light switch is the blackout drive light e The front and rear marker lamps will illuminate control e The blackout stop lamps will illuminate when the brakes are applied The service lights blackout control switch must be in f blackout position or in the down position for the e The instrument panel warning lights will blackout drive lights to function remain functional The hazard lights will remain functional a The hom will not D
16. an injure you badly Keep your hands away from moving part once the engine is running 5 Connect the positive cable to the positive side of the 12 volt battery 12 volt side of the vehicle with the dead battery 5 5 Connect the negative cable to the negative post of the 12 volt system of the vehicle with the good battery Do not let the other end touch anything until the next step The other end of the negative cable does not go to the dead battery lt goes to a heavy unpainted metal part of the engine in the vehicle with the dead 6 Connect the positive cable to the positive battery side 12 volt system of the vehicle with the good battery 8 Attach the cable at least 45 cm 18 in away from the dead battery but not near engine parts that move The electrical connection is just as good there but the chance of sparks getting back to the battery is much less 5 6 9 Start the vehicle with the good battery Allow the vehicle to charge for 10 minutes before attempting to start the vehicle Note lt may take up to 30 minutes to charge the battery pending on the battery s state of charge 10 Start the vehicle with the dead battery 11 Remove the cables in reverse order to prevent electrical shorting Take care that they do not touch each other or any other metal A 12 Volt Positive Dead Battery B 12 Volt Positive Good Battery C 12 Volt Negative Good Battery D
17. aps 14 To reinstall the cargo cover reverse Steps 1 through 13 Cargo Tie Downs If Eguipped Four cargo tie downs A are provided on each side of the rear cargo area The cargo tie downs are used to strap cargo in and keep it from moving inside the cargo area Each of these rings are rated for a maximum pull of 660 lbs 300 kg upward or 450 Ibs 200 kg of horizontal force Weapons Mount Floor Mount Weapon Mount Crew Cab If the weapon is improperly stored it can move around in a collision or sudden stop People in the vehicle could be injured Be sure to secure any such item properly The weapon should be made safe when stored in this mount The floor mount weapon mount is located behind the front seats and will secure two weapons Mounting the Weapon Place the stock of the weapon into the lower mount and the barrel into the upper mount until fully seated in the clamp and secure with strap Behind Seat Weapon Mount Standard Cab Lower Weapon Holder Upper Weapon Holder PB I To secure weapons in the vehicle first place the Place the barrel into the upper weapon support Pull stock in the lower weapon support the strap outward and slide it over the barrel of the rifle and secure buckle 2 9 NOTES 2 10 Section3 Instrument Panel Exterior Lamps 3 2 Interior Lamps Lusuuuuueesee 3 6 Service and Blackout Lighting 3 2 Topper DomeL
18. e the fabric and look for deterioration If the canvas has deteriorated replace it Refer to cargo cover replacement in the 2003 LSSV Military Trucks Service Manual Supplement Vehicle Information Shipping Data Plate SHIPPING DATA PLATE PLAOUE DE DONNEES D EXPEDITION MOD K25743 2283 oce Kam d as ALL DIMENSIONS ARE N MILLIMETERS TOUTES LES DIMENSIONS SONT EN MILL METRES mn __ ww a a VOLUME IH X WX LI 24 60 The data plate is used to inform the owner of the vehicle as to the make model Gross Vehicle Weight GVW and vehicle dimensions lt is located on the left front inner door panel Government Vehicle Data Plate CURB WEIGHT DA PAYLOAD GVWR GCWR ERA ES DATE OF Mr 9 WARRANTY MI MONTHS S 6j CONTRACT NO rm A PART KG Sees The data plate used to inform the owner of the vehicle as to the upfitting information and other specifications It is located on the left front inner door panel Electrical System Fuses and Circuit Breakers Circuit breakers protect the power accessories When the current load is too heavy the circuit breaker opens and closes protecting the circuit until the problem is fixed or goes away 24 Volt Circuit Breakers These circuit breakers are on the left rear fender support bracket of the engine compartment A 24 Volt Stud on Egualizer C Fuel Fired Heater B 24 Volt Stud on Egualizer Cover D Auxiliary ltem
19. efore operating the heater To Prevent Fire DO NOT operate heater where flammable or explosive materials gases or dusts may be present DO NOT operate heater over dry grass or other dry ground cover Switch heater off while refueling vehicle Switch heater off BEFORE entering fueling stations To Prevent Burning NEVER touch hot components of the heating system Your heater is a diesel powered supplementary heating system that will heat the engine coolant of your vehicle This will prevent cold start up of the engine it can be used in conjunction with the factory coolant heater 24 Fuel Fired Coolant Heater Operation The fuel fired coolant heater is controlled by a toggle switch located on the instrument panel I P bezel to the left of the steering column The heater is activated by moving the switch A to the ON position An indicator lamp will illuminate the switch To deactivate the heater move the switch to the OFF position If the switch is in the ON position and flashing there is a problem with the system Refer to the 2003 LSSV Service Manual Military Supplement Turn the fuel fired coolant heater OFF when not in use Storage Areas 4 Unzip the front and rear panels Cargo Cover Soft Top If Eguipped 5 Roll the sides upward If the vehicle is equipped with a soft top cargo cover it must be fully installed and properly anchored before 6 When the sides reach the top they can be held in travelin
20. er the Hood 5 2 Engine Component Overview 5 2 Jump Starting ce teas dee hee de eed 5 3 Jump Starting from a 12 Volt System 5 3 Slave Starting eis nea tat eee 5 8 Cleaning the Outside of the Vehicle 5 12 Cleaning the Soft Top Cargo Cover 5 12 Customer Assistance Information 7 2 Contactlnformation 7 2 Driving Your Vehicle ess a a ii Electrical System iu Yu RY peru gd 5 14 Fuses and Circuit Breakers 5 14 24 Volt Circuit Breakers 5 14 24 Volt Power SourC8 Y 5 2 Engine Component Overview 3 2 Exterior Lamps Re YA ei YL YE 3 2 Service and Blackout Lighting 3 2 Blackout DriveLamp 3 2 Operating Service and Blackout Lighting 3 3 Foia Seats Down she 0 20 a eee eee 1 2 Fold Seats Up e e REA 1 3 Front Axle Vent Tube Filter 5 10 Front Clevis Towing Provisions 4 5 Front Rear Axle Inspection 6 2 Fuel Fired Coolant Heater 2 4 Fuel Fired Coolant Heater Operation 2 4 Fuses and Circuit Breakers 5 14 Fuel Fired Coolant Heater Inspection 6 3 Government Vehicle Data Plate 5 13 l you re Stuck In Sand Mud Ice or Snow 4 6 Using the Clevis Towing Provisions 4 6 Front Clevis Towing Provisions 4 6 Rea
21. g on the highway place by inserting the cargo cover straps in the The sides of the cargo cover can be rolled up clips at the top of the cargo cover Rolling Up the Side Panels Storing the Cargo Cover 1 Release tension on hooks by pushing release on the front of the hook 2 Remove the plastic hook from the bed fastener 3 Unsnap the flaps on both side panels near the truck cab to expose the zipper 4 Unzip the front and rear panels 5 Release the two cover straps located inside the cargo box near the truck cab that attach the cover to the cargo box 1 To release tension on hooks push release on the front of the hook 6 Remove the canvas cover from the cargo cover bows 2 Remove plastic hook from the bed fastener 7 Fold the cover neatly and store it behind the seat 3 Unsnap the flaps on both side panels near the in the truck cab truck cab to expose the zipper 2 5 8 Release the two front and rear corner support straps 2 6 a WAW 9 Remove the six guick release pins from the sides of the cargo cover bows 10 To get the bows to stack on top of each other without striking the cab or the troop seats if eguipped push down egually on both sides of the upper part of the front and rear bows 11 Pull upward equally on both sides of the upper part of the center bow 12 Standing at the rear of the vehicle push the bows forward 13 Secure the bows in place with the front support str
22. inch will only work with the remote How the Winch Reacts to Load The winch is rated at maximum pulling capacity This occurs on the first layer of wire rope on the drum As the layers increase the pulling power decreases Exceeding the winch capacity could cause the winch to fail or the wire rope to break Winch Accessory Kit 4 4 The Winch Accessory Kit Contains the Following Items e Tow Hooks Secure porperly to your vehicle s frame tow hooks provide an attachment point for wire rope straps and chains e Clevis D Shackles The D Shackle is a safe means for connecting the looped ends of cables straps and snatch blocks e Snatch Block Used properly the multi purpose 24 000 lbs 10 886 kgs snatch block allows you to do he following Increase your winch s pulling power Change your pulling direction without damaging the wire rope e Choker Chain Can be used to hook up to another vehicle or sharp objects for an anchor point e Gloves Wire rope through use will develop barbs which can slice skin e Recovery Straps Used to snatch or pull out astuck vehicle e Tree Truck Protector Use this with a clevis d shackle to secure the wire rope to an anchor point 4 5 If You Are Stuck In Sand Mud Ice or Snow Using the Clevis Towing Provisions The vehicle is eguipped with two clevises on the front and rear ends of the vehicle CAUTION The clevises when used are under a lot
23. ment correspond to the th hicl reci mavsr culcia lose of control or sections in the 2003 C K Owner s Manual and the eee Seley THI 2003 Duramax Diesel Manual Supplement This GAED Healer I CYDUFTEITVIGHIS me Ong ang supplement along with your owner s manual and Your Vehicle and Off Road Driving with Your Four diesel supplement will assist you in the proper use Wheel Drive Vehicle in the 2003 C K Truck Owner i Manual of the vehicle Please keep this supplement with the owner s Safety Warnings and Symbols manual and diesel supplement m the vehicle So It You will find a number of safety cautions in this book will be there if you ever need it while you re on the We use a box and the word Caution to tell you about road things that could cause personal injury if you were to This manual includes the latest information at the ignore the warning time it was printed We reserve the right to make changes in the product after that time without notice N CAUTION Index These mean there is something that could hurt A good place to look for what you need is the Index you or other people in back of the manual It s an alphabetical list of what s in the manual and the page number where you ll find it Copyright General Motors Corporation 00 00 03 All Rights Reserved General Motors and GM are registered trademarks of General Motors Corporation Part No TX017816 First Edition Litho in USA In the caution area we tell you
24. n Signal Hazard Warning Indicators SERVICE ON OFF Four Wheel Drive Indicator SERVICE ON OFF Dome Courtesy Lamps SERVICE ON OFF Glove Compartment Lamp SERVICE ON OFF Warning Chime Headlamps On SERVICE ON ON OFF Instrument Cluster Warning Lights Clock numerals and DRL indicator will remain illuminated Mechanical Device Service Lights Blackout Switch Blackout Drive Light Switch Automatic Transmission SERVICE ON ON OFF Shift lock Control Torque Converter Lockup Clutch SERVICE ON ON OFF Interior Lamps Topper Dome Lamp The fiberglass topper dome lamp is controller by a master switch on the side of the dome lamp and a pair of 3 way switches With Blackout Lighting The interior 3 way switch A is located on the blackout switch panel Without Blackout Lighting The interior 3 way switch A is located on the instrument panel I P bezel to the left of the steering column The bed mounted 3 way switch A is located in the left rear of the cargo bed The topper mounted master switch A is located on the rear center of the topper roof If the master switch is turned OFF the following will occur e The interior mounted 3 way switch will not function e The bed mounted 3 way switch will not function The dome lamp will not function in the blackout position 3 7 Warning Lights Gages and Indicators 24 Volt Voltmeter The 24 volt voltmeter is located in the instrument panel next to the service and black
25. nd is NOT in NEUTRAL N Turn off the ignition on both vehicles Unplug unnecessary accessories plugged into the cigarette lighter or accessory power outlets Turn off all lamps that are not reguired as well as radios This will avoid sparks and help save both batteries In addition it could save your radio Notice If you leave your communications navigation eguipment on there is a risk that they could be badly damaged The repairs wouldn t be covered by your warranty 3 Ensure the jumper cables do not have loose or missing insulation If they do you could get shocked The vehicles could be damaged too 4 Open the hoods and locate the batteries Find the positive and negative terminals on each battery Using a open flame near a battery can cause battery gas to explode People have been hurt doing this and some have been blinded Use a flashlight if you need more light Be sure the batteries have enough water You don t need to add water to the Delco Freedom battery or batteries installed in every new GM vehicle But if a battery has filler caps be sure the right amount of fluid is there If it is low add water to take care of that first If you do not explosive gas could be present Battery fluid contains acid that can burn you Do not get it on you If you accidentally get it in your eyes or on your skin flush the place with water and get medical help immediately Fans or other moving engine parts c
26. ndle upward to open the jaw of the hitch 4 Lift the upper part of the hitch upward 5 Attach the trailer tongue to the lower part of the hitch 6 Push the jaw of the hitch downward then pull upward to make sure the hitch is secured 7 Insert the locking pin into the hole on the side of the hitch Removing the Pintle Hitch 1 Remove spring clip from retaining pin 2 Remove retaining pin from receiver 3 Pull the pintle hitch out of receiver Installing the Pintle Hitch 1 Remove any debris from the inside of the receiver 2 Push pintle hitch B into the receiver 3 Install retaining pin C into the receiver and the pintle hitch B 4 Install spring clip A into the retaining pin C Trailer Wiring Connector On the military bumper the NATO standard 12 pin trailer lamp and brake connector is located on the rear bumper between the clevis tie down and the pintle hitch On the factory bumper the NATO standard 12 pin trailer lamp and brake connector is located on the rear trailer hitch to the left of the pintle hitch When connecting a trailer wiring harness to the connector make sure the dog ears of the connector are properly aligned when inserting it into the connector Trailer Connector Adapter When connecting to a commercial trailer with an 8 pin connector the adapter must be used This adapter allows you to connect an 8 pin trailer wiring harness into the vehicles 12 pin connector
27. o provide power to start the vehicle NATO slave cables are the only recommended method for 24 volt jump starting of the vehicle You should only use NATO slave cables to jump start similar vehicles Heavy duty jumper cables can be used to jump start the 12 volt system Refer to Jump Starting from a 12 volt System Jump Starting from a 12 Volt System CAUTION Batteries can hurt you They can be dangerous because O They contain acid that can burn you O They contain gas that can explode or ignite O They contain enough electricity to burn you If you do not follow these steps exactly some or all of these things can hurt you Notice Ignoring these steps could result in costly damage to your vehicle that would not be covered by your vehicle warranty Trying to start your vehicle by pushing or pulling it will not work and it could damage your vehicle 5 3 This procedure applies only to the 12 volt battery located on the passenger s side of the vehicle 1 Get the vehicles close enough so the jumper cable scan reach but be sure the vehicles are not touching each other If they are it could cause a ground causing vehicle not to start The bad grounding could damage the electrical systems To avoid the possibility of the vehicles rolling set the parking brake firmly on both vehicles involved in the jump start procedure Put the automatic transmission in PARK P Be sure the transfer case is in a drive gear a
28. ockwise 90 2 Pull open window door A cylinder on both sides of window will assist with opening and hold window in the open position Closing Rear Window Door 1 Pull window door down 2 Turn both handles A counter clockwise 90 2 2 Side Topper Window Open the Side Window Doors 1 Turn both handles A clockwise 90 2 Pull open window door A cylinder on both sides of window will assist with opening and hold window in the open position Closing the Side Window Doors 1 Pull window door down 2 Turn both handles A counter clockwise 90 Sliding Rear Window Starting and Operating The vehicle may be eguipped with a sliding rear Your Vehicle cab window Starting Your Engine Your diesel engine starts differently than a gasoline engine N CAUTION Do not use gasoline or starting aids such as ether in the air intake They could damage your engine There could also be a fire which could Opening the Rear Window cause serious personal injury 1 Open the latch in the center of the window Refer to 2003 Duramax Diesel Engine Supplement 2 Slide the window to the open position located in your glove compartment Closing the Rear Window Slide the window to the closed position until the latch is fully engaged Fuel Fired Coolant Heater To Prevent Asphyxiation DO NOT operate while in confined spaces such as closed unventilated enclosures Open an outside enclosure door b
29. onnect the slave cable to the vehicle with the good battery 7 Allow the vehicle with the dead battery to charge for 10 minutes Note lt may take up to 30 minutes to charge the baitery pending on its state of charge 8 Start the vehicle with the dead battery 9 Remove the slave cable in the reverse order that it was installed Take care not to let the cable ends touch each other or any other metal 5 10 Vent Filters Rear Axle Vent Tube Filter The rear axle vent tube filter is located on the vent hose that is attached to the top of the axle housing Refer to the Maintenance Schedule to determine how often to inspect the filter and when to change it Refer to Front Rear Axle Inspection Transfer Case Vent Tube Filter The transfer case vent tube filter is located on the driver s side of the transfer case housing Refer to the Maintenance Schedule to determine how often to inspect the filter and when to change it Refer to Transfer Case Inspection Front Axle Vent Tube Filter The front axle vent tube filter is located in the engine compartment near the left inner wheel well Refer to the Maintenance Schedule to determine how often to inspect the filter and when to change it Refer to Front Rear Axle Inspection Bulb Replacement Tires Lamp Bulb Number Changing a Flat Blackout Headlamp EAS Topper Dome Lamp 24 Volt Gage Lamp License Plate Lamp Note The bulbs in the blackout tail stop lamp and fr
30. ont marker lamps are light emitting diodes LED instead of incandescent bulbs They are not replaceable and are serviced as an assembly For bulb replacement refer to the 2003 LSSV Military Trucks Service Manual Supplement The military heavy duty bumper of the vehicles have an opening A to gain access to the spare tire hoist For more information see Changing a Flat Tire in the 2003 C K Truck Owner s Manual 5 11 Inflation Tire Pressure Tire pressure should be within the manufacturer s recommended range as indicated on the certification tire label which is on the drivers door edge When hauling heavy loads the pressure should be at the maximum allowable pressure Refer to Inflation Tire Pressure in The 2003 C K Truck Owner s Manual for additional information on tire inflation pressure Appearance Care Cleaning the Outside of the Vehicle Wash the vehicle using only mild soap and water Do not use cleaning agents that are petroleum based or that contain acid or abrasives All cleaning agents should be flushed promptly and not allowed to dry on the surface Do not towel dry or wax the paint surface 5 12 Cleaning The Soft Top Cargo Cover The cargo cover is a rain resistant canvas top Areas with mildew should be cleaned by scrubbing with a dry brush Never use solvents If necessary to use water to remove dirt it should not be used until the mildew has been removed After removing the mildew examin
31. out lighting switch Load Reading No Load Reading The voltmeter needle should be in the green band The voltmeter needle should be between the yellow during normal load operation If the needle is not in and the green bands in a no load situation the green band the fuse may have blown If the fuse is not blown and the system still does not work properly report it to your maintenance support NOTES 3 9 Section4 Driving Your Vehicle Your Driving the Road and Your Vehicle 4 2 Towing eie gi WL CY RETI ETE 4 8 Loading Your Vehicle 4 2 Towing Your Vehicl amp 4 8 WINCH bition e doh gee mp hn ha ede ete 4 3 Towing a Trailef 4 8 Winch Accessory Kit 4 4 If You Are Stuck In Sand Mud Ice or Snow 4 5 Using The Clevis Towing Provisions 4 5 Your Driving The Road and Your Vehicle Loading Your Vehicle Make sure that all cargo is properly secured to prevent the load from shifting All loads must be AN CAUTION distributed evenly over the axle and secured to the tie down rings provided Refer to Loading Your Do not load your vehicle any heavier than the Vehicle in the Index of the 2003 C K Truck Owner s GVWR or either the maximum front or rear Manual for more information on vehicle loading GAWR If you do parts on your vehicle can break or it can change the way your vehicle If the vehicle is equipped with troop seats you
32. r Clevis Towing Provisions 4 6 Maximum Allowable Loads On Each Clevis Towing Shackle d4 4 7 Inflation Tire Pressure 5 12 Install the Pintle Hitch 4 10 Interior Lamps Y ug 3 6 Topper DomeLamp 3 6 8 1 J ump Starting YY ug 5 3 Jump Starting from a 12 Volt System 5 3 Loading Your Vehicl amp 4 2 Maintenance Schedule 6 2 Front Rear Axle Inspection 6 2 Transfer Case Inspection 6 2 Fuel Fired Coolant Heater Inspection 6 3 Winch Inspection 6 3 Maximum Allowable Loads on Each Clevis Towing Shackle ie ici idas haha 4 7 Mount the Weapon 2 8 Multi Mount Winch sareste rades pickin ny peaa 4 3 Operate the Pintle Hitch ee ee ed 4 10 Operating Service and Blackout Lighting 3 4 Permanent Mount Winch 4 4 Pintle Hitch rie e y 4 10 To Operate the Pintle Hitch 4 10 To Remove the Pintle Hitch 4 10 To Install the Pintle Hitch 4 11 Rear Axle Vent Tube Filter 5 10 Rear Clevis Towing Provisions 4 6 Rear Topper Window llle seres 2 2 Remove the Pintle Hitch 4 10 Replacement Bulbs 5 11 RestraintSe uie ecrit ich Ec Rydd Ud iw a 1 4 aet Safety Strap
33. s 24 Volt Power Source Battery Egualizer The battery egualizer is located on the left rear of the cab The primary function of the battery equalizer is to maintain battery balance or egualization charge in a predominately 24 volt system which requires regulated 12 volt power The battery egualizer can deliver up to 100 amps of continuous 12 volt current for practically any 12 volt or 24 volt load such as two way radios navigations or the 24 volt batteries NOTES 5 15 Section6 Maintenance Schedule Maintenance Schedule 6 2 Transfer Case Inspection 6 2 Front Rear Axle Inspection 6 2 Fuel Fired Coolant Heater Inspection 6 3 Winchlnspection 6 3 6 1 Maintenance Schedule Front Rear Axle Inspection Inspect the front rear axle fluid level and add as needed Inspect the constant velocity joints and axle seals for leakage The front and rear axles are eguipped with an in line filter on the vent tubes Inspect the filters for blockages and replace as needed Refer to Front Axle and Rear Axle in the Index for further information on the location of the front and rear axle filters Refer to Maintenance Schedule in The 2003 C K Truck Owner s Manual for additional maintenance information on the vehicle Transfer Case Inspection Inspect the transfer case fluid levels and add lubricant if necessary On manual shift transfer case oil
34. sese rada 1 4 Safety Warnings and Symbols ii Service and Blackout Lighting 3 2 Side Topper Window YY a 2 2 Sliding Rear Window V eee eee 2 3 Staring and Operating Your Vehicle 2 3 Starting Your Engine ep e 2 3 Storage Areas ise eek ew E Y x eas 2 5 Cargo Cover Soft Top aaa 2 5 Tires Tr 5 11 Changingia Plate aba EU Yu t eia bee 5 11 Inflation Tire PresSur amp 5 12 Topper DomeLamp c 3 6 TOWING si o e dd dyd i voe E Rar tte Da is ae 4 8 Towing Your Vehicle 4 8 Towing a Trailer llle 4 8 Weight of the Trailer o oooo oooooooo 4 9 Trailer Connector Adaptor 4 12 Trailer Wiring Connector c 4 11 Transfer Caselnspection 6 2 Transfer Case Vent Tube Filter 5 10 Troop Seats ss usse dde Rode ec Rl dn 1 2 Fold Seats DOwn YY Y uu 1 2 Fold Seats UD see esed 1 3 24 Volt Circuit Breakers 5 14 24 Volt Power Source eee ee eee 5 14 24 Volt Voltmeter 2 2 eee 3 8 Using Clevis Towing Provisions 4 6 Vehicle Damage WarningS lt iii Vehicle Information 5 13 Government Vehicle Data Plate 5 13 Shipping Data Plate V uu 5 13 VentlFiltefSe beste BAG KA NAGA
35. what the hazard is Then we tell you what to do to help avoid or reduce the hazard Please read these cautions If you don t you or others could suffer personal injury Vehicle Damage Warnings Also in this supplement manual you will find these notices Notice These mean there is something that could damage your vehicle In the notice area we tell you about something that can damage your vehicle Many times this damage would not be covered by your warranty and it could be costly But the notice will tell you what to do to help avoid the damage When you read other manuals you might see CAUTION and NOTICE warnings in different colors or in different words You l also see warning labels on your vehicle They use the same words CAUTION or NOTICE Section 1 Seats and Restraints Troop Seats LL Lu 1 2 RestraintS I L L Y uu 1 4 To Fold the Seat Down 1 2 Rear Safety Strap 1 4 ToFoldtheSeatUp 1 3 1 1 Troop Seats If Eguipped 1 A guick release pin is located on the left or right The troop seat kit provides space for up to eight side o the troop seat leg immediately under the passengers in the cargo area of the pickup model hinge pin The seats can be lowered individually for use or 2 When the seat is in the up position the guick raised for storage The seats lock in both the up and release pin will go through the left hand
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