2004 LSSV Owner`s Manual Supplement
Contents
1. sssss 5 11 W Warning Lights Gages and Indicators 3 7 24 Volt Gage nad Weapons MOUNT ssie iuit tact veg e tt renting Weapons Mount Floor Mount Weapons Mount Cab Mount Winch Provislons cce cete tetro eene ide etel WINDOWS oi teretes Rear Topper Window Side Topper Window cerent 2 2 Sliding Rear Window eee 2 3 Your Driving the Road and UNE Vehicle E 4 2 Loading the Vehide 5 2 net 4 2 www gm defense com2. 3 3 Operating Service and Blackout Lighting 3 4 F Folding the Seat Down Troop Seat 1 2 Folding the Seat Up Troop Seat 1 3 Front Axle Vent Tube Filter ess 5 11 Front Clevis Towing Provisions eese 4 4 Front Rear Axle Inspection eese 6 2 Fuses and Circuit Breaker eee 5 16 G Government Vehicle Data Plate 5 15 How to Use This Manual sse ii If You re Stuck in Sand Mud Ice or Snow 4 3 Using the Clevis Towing Provisions 4 3 Front Clevis Towing Provisions 4 4 Rear Clevis Towing Provisions 4 5 Inflation Tire Pressure see 5 14 Installing the Pintle Hitch see 4 7 Interior LAM PS esis usine che nth in eei eee rores 3 6 Topper Dome Lamp ssssseeeen 3 6 JUMP SErtifigi s etm era iet te a a RREA 5 4 Jump Starting from a 12 Volt System 5 4 Loading the Vehicle 1 senidinae iia 4 2 Maintenance Schedule sssssssssssss 6 2 Front Rear Axle Inspection sess 6 2 Transfer Case Inspection
3. sssusss 6 2 Mounting the Weapon seen 2 7 Operating the Pintle Hitch eee 4 7 Operating Service and Blackout Lighting 3 4 Pintle Hite heerser dati etc free an ed oa 4 7 Operating the Pintle Hitch esssss 4 7 Installing the Pintle Hitch eeeeeesss 4 7 R Rear Axle Vent Tube Filter esses 5 11 Rear Clevis Towing Provisions sesss 4 5 Rear Topper Window eee 2 2 Replacement BuIDS su 3 2 1n kn vis 5 13 cl ee 1 3 Rear Safety Strap 5i einer hdc 1 3 S Safety Warnings and Symbols sseesssss iii Service and Blackout Lighting sess 3 2 Side Topper Window sse 2 2 Shipping Data Plate inrcr 5 15 Slave Starting Using 24V NATO Connector 5 9 Sliding Rear Window eee 2 3 Starting and Operating the Vehicle 2 3 Starting the Engine iconic 2 3 Storage Areas nini voted rn E 2 5 Cargo Cover Soft Top 2 5 Rolling Up the Side Panels 2 5 Storing the Cargo Cover see 2 5 I c Changing a Flat Tire Inflation Tire Pressure
4. see 5 14 Topper Dome Lamp sse 3 6 I o 4 6 Towing the Vehicle anios nisn ernea 4 6 Towinga Trailer iieri 4 6 Trailer Connector Adapter Tahoe Only 4 8 Trailer Wiring Connector nee 4 8 Transfer Case Inspection sees 6 2 Transfer Case Vent Tube Filter sess 5 11 TfOOp S68l8 5 2 erae eigde 1 2 Troop Seat Operation sees 1 2 Folding the Seat Down sies 1 2 Folding the Seat Up 2 titt 1 3 Circuit Breaker Tahoe Only sees 5 16 24 Volt Power Source Tahoe Only 5 16 24 Molt Gage Lunar anden 3 7 U Underhood Component Locator Silverado 5 2 Underhood Component Locator Tahoe 5 3 Using JPS8 as aFuel iiie Sete 4 2 Using the Clevis Towing Provisions 4 3 Vehicle Damage Warnings eee iii Vehicle InforimallOn ciii tt mice ir eara taces 5 15 Government Vehicle Data Plate 5 15 Shipping Data Pl t Irt 5 15 Ment Filles ip prit reete terere rite Fe dotar Ped errata d 5 11 Rear Axle Vent Tube Filter 5 11 Transfer Case Vent Tube Filter 5 11 Front Axle Vent Tube Filter
5. 2004 General Motors Light Service Support Vehicle LSSV Military Truck Owner s Manual Supplement Seats and Restraints Systems ssss 1 1 11 010 PS C 1 2 368lrallil Seir eer rei eee errr et pectet ries ero ei edic reeretr 1 3 Features and Controls sss 2 1 WINdOWS eneen 2 2 Starting and Operating the Vehicle 2 3 Vehicle Load Disconnect Switch 2 4 Storage Areas nie pere tet cepe cut 2 5 Weapons Mount nnns 2 7 Instrument Panel sse 3 1 Exterior Lamps serenos noinen ceteri ann nece ad ender 3 2 Interior Lamps ieu erede tet ines 3 6 Warning Lights Gages and Indicators 3 7 Driving The Vehicle sss 4 1 Your Driving the Road and the Vehicle 4 2 o E 4 6 Service and Appearance Care ss 5 1 Underhood Component Locator Silverado 5 2 Underhood Component Locator Tahoe 5 3 J rmp Starthg nece tm eer eese 5 4 Vent FIITeIS inier Cere reet eee 5 11 Bulb Replacement 5 niece 5 12 Replacement Bulbs sss 5 13 Appearance Care rere 5 14 Vehicle Information ene 5 15 Electrical System nain 5 16 Maintenance Schedule sess 6 1
6. 24 Volt Gage eee ene etennte tnnt tnntt 3 7 Exterior Lamps Service and Blackout Lighting BLACKOUT DRIVE LIGHT SERVICE ON LIGHTS re Q Der 2 en E I Notice If the vehicle is not going to be driven for 24 hours or more the service lights switch must be placed in the ALL OFF position This will help prevent drain on the batteries Notice Before normal driving operations turn on service lights to ensure headlights brake lights and turn signals are operational 3 2 Service Lights Blackout Control The switch located on the blackout switch panel next to the 24 volt gage is the service lights blackout control With the Ignition Switch in the ON Position Pull the switch outward then push upward to the service ON position All normal service lamps will be operational with normal controls Move the service lights blackout switch to the center ALL OFF position All lamps and accessory power to the vehicle will turn off Move the switch to the blackout position the following will occur The blackout lighting system will be operative The front and rear blackout marker lamps will illuminate The blackout stop lamps will illuminate when the brakes are applied The instrument panel warning lights will remain functional The hazard lights will remain functional The horn will not be functional The vehicle s military 12 pin trailer wiring connector and trailer la
7. release on the front of the hook Remove the plastic hook from the bed fastener Pull apart the velcro flaps on both side panels near the vehicle cab Pull apart the velcro flaps on both panels near the back of the vehicle Release the six cover straps located inside the cargo box that attaches the cover to the cargo cover bows Remove the cover from the cargo cover bows Fold the cover neatly and store it behind the seat in the truck cab 2 5 8 Release the four corner support straps 9 Remove the six quick release pins from the sides of the cargo cover bows 2 6 10 Stack the bows on top of each other without striking the cab or the troop seats if equipped push down equally 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 straps 14 To reinstall the cargo cover reverse Steps 1 13 Note The cargo cover is marked with the word FRONT on the inside top to aid in proper positioning of the cover onto the vehicle Weapons Mount Mounting the Weapon Weapon Mount Floor Mount 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
8. A cylinder on both sides of the window will assist with opening and hold the window in the open position Closing the Side Window Doors 1 Pull the window door down 2 Turn both handles A counter clockwise 90 Notice The window must be fully closed before operation of the vehicle Sliding Rear Window If the vehicle is equipped with a sliding rear window it features tempered glass surrounded by a durable black finish aluminum frame and three panel design Locking latch adds cab security To open the window hold the latch in the open position and slide the window open To close the window slide the window until the latch is fully engaged against the frame roing Starting and Operating the Vehicle Starting the Engine The 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 the engine There could also be a fire which could cause serious personal injury Refer to the 2004 Duramax Diesel Engine Owner s Manual Supplement located in the glove compartment 2 3 Vehicle Load Disconnect Switch The load disconnect switch is located on the underhood fuse block The underhood fuse block is located on the If the vehicle is equipped with a load disconnect switch AES side OLE vehicle to the rear of VE alen the switch disconnects 12 volt vehicle loads and 24 volt trailer aux loads that could cause a
9. break or it can change the way the vehicle handles These could cause you to lose control Also overloading can shorten the life of the vehicle Notice The warranty does not cover parts or components that fail because of overloading 4 2 Make sure that all cargo is properly secured to prevent the load from shifting All loads must be distributed evenly over the axle and secured to the tie down rings provided Refer to Loading Your Vehicle in the Index of the 2004 Vehicle Owner s Manual for more information on vehicle loading If the vehicle is equipped with troop seats you can carry up to eight passengers Passengers must stay seated at all times and the rear safety strap in place Winch Provisions Front The front of the vehicle is equipped with a winch receiver B and a 12 volt quick disconnect A is provided to power the winch A 15365 Rear The rear of the vehicle s pintle hook mounts B can be AN CAUTION used for the winch The 12 volt quick disconnect A is The clevises when used are under lot of force provided to power the winch 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
10. 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 Optima battery or batteries installed in every 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 the eyes or on the skin flush the place with water and get medical help immediately 5 6 Fans or other moving engine parts can injure you badly Keep your hands away from moving parts once the engine is running 5 Connect the positive cable to the positive terminal of the 12 volt battery 12 volt side of the vehicle with the dead battery Connect the negative cable to the negative terminal 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 It 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 terminal 12 volt system of the vehicle with the good battery 8 Attach the cable at least 18 in 45 cm away from the de
11. t be covered by the vehicle warranty Trying to start the vehicle by pushing or pulling it will not work and it could damage the vehicle You should only use the NATO slave receptacle and slave cable when performing this operation 1 Get the vehicles close enough so that the slave cable can reach but be sure the vehicles are not touching each other If they are it could cause a ground connection causing the 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 N 5 9 2 Turn off the ignition on both vehicles Unplug unnecessary accessories plugged into the cigarette AN CAUTION lighter or accessory power outlets Turn off all lamps that aren t needed as well as radios This will avoid Using a open flame near a battery can cause battery sparks and help save both batteries In addition it gas to explode People have been hurt doing this could save the radio and some have been blinded Use a flashlight if you Notice If you leave the communications navigation needmore light equipment on they could be badly damaged The repairs will not be covered by the warranty Be sure the batteries have enough water You don t need to add water to the Optima batte
12. 6L vehicle A Rear Winch Feed 12V Power D 24 Volt Relay B 24 Volt Generator E Load Disconnect Switch C 24 Volt Generator Fuses F 24 Volt Battery 5 2 Underhood Component Locator Tahoe The following items are military options that may be found on the 5 3L vehicle A Rear Winch Feed 12V Power B Circuit Breakers C 24 Volt Battery 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 to 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 See Jump Starting from a 12 volt System 5 4 Jump Starting from a 12 Volt System 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 ofthese things can hurt you Notice Ignoring these steps could result in costly damage to the vehicle that would not be covered by the vehicle warranty Trying to start the vehicle by pushing or pulling it will not work and it could damage the vehicle This procedure applies only to the underhood battery located on the passenger s side of the veh
13. Maintenance Schedule sssssssss 6 2 Customer Assistance Information 7 1 Customer Assistance Information 7 2 WOK T 8 1 The information in this manual pertains to the operation of the vehicle It also contains the vehicle s scheduled maintenance services This manual along with the owner s manual will assist you in the proper use and maintenance of the vehicle The sections in this supplement correspond to the sections in the 2004 Vehicle Owner s Manual and the 2004 Duramax Diesel Engine Owner s Manual Supplement Please keep this supplement with the owner s manual and diesel supplement in the vehicle so it will be there if you ever need it while you re on the road Litho in USA Part No LSSVOMO4 First Edition ii This manual includes the latest information at the time it was printed We reserve the right to make changes in the product after that time without notice How to Use This Manual Many people read the owner s manual from beginning to end when they first receive the vehicle If you do this it will help you learn about the features and controls for the vehicle In this manual you ll find that pictures and words work together to explain things 9 Copyright General Motors Corporation 08 23 04 All Rights Reserved Index A good place to look for what you need is the Index in back of the manual It s an alphabetical list of what s in th
14. ad 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 7 9 Start the vehicle with the good battery Allow the vehicle s battery to charge for 10 minutes before attempting to start the vehicle Note It may take up to 30 minutes to charge the battery enough to start the vehicle depending 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 5 8 12 Volt Positive Dead Battery 12 Volt Positive Good Battery 12 Volt Negative Good Battery Engine Ground Dead Battery Dom If this procedure does not work you will need to disconnect the left front underhood battery and charge it alone for 10 minutes Reconnect the battery and repeat the jump starting procedures as outlined Note This procedure should only be performed by authorized personnel Slave Starting Using 24V NATO Connector 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 hurt you Notice Ignoring these steps could result in costly damage to the vehicle that wouldn
15. ailer towing 4 6 The vehicle is equipped with a pintle hitch for towing a trailer You must not exceed the maximum trailer weight towing capacity for that vehicle Refer to Towing a Trailer in the Index of the 2004 Vehicle Owner s Manual for additional information Pintle Hitch To Open A pintle hitch is located at the rear of the vehicle and 1 Open the latch by removing latch pin F is removable from the receiver 2 Pull up on the lock latch C while lifting the latch D Notice Before operating inspect for proper operation worn damaged or missing parts and secure mountings To Close Correct as required before use 1 Push the latch D until the lock latch C locks in place Operating the Pintle Hitch 2 Install the latch pin F Installing the Pintle Hitch 1 Remove any debris from the inside of the receiver 2 Push the pintle hitch E into the receiver 3 Install the retaining pin B into the receiver and the pintle hitch E 4 Install the spring clip A into the retaining pin B Trailer Wiring Connector The NATO standard 12 pin trailer lamp and brake connector is located on the rear bumper between the right clevis tie down and 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 Tahoe Only The vehicle may be equipped wit
16. both front or rear clevises with If You Are Stuck In Sand Mud Ice or a V device to gain an even pull on both anchor points Snow and avoid damage to the vehicle Using the Clevis Towing Provisions The vehicle is equipped with two clevises on the front and rear ends of the vehicle Front Clevis Towing Provisions Factory Bumper Note Clevises meet MIL 209J for tie down specifications Vehicles do not meet MIL 209J for vehicle lifting Rear Clevis Towing Provisions Factory Bumper Maintenance Bumper Note Clevises meet MIL 209J for tie down specifications Vehicles do not meet MIL 209J for vehicle lifting Towing Towing The 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 2004 Vehicle 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 position The vehicle transfer case must be in NEUTRAL N Towing a Trailer The vehicle is equipped for towing a trailer Notice Do not exceed the maximum allowable weight the vehicle is designed to carry Exceeding the maximum allowable weight may cause damage to the vehicle Refer to Towing a Trailer in the Index of the 2004 Vehicle Owner s Manual for more information on tr
17. d Controls WindOws cine n ee 2 2 Storage Areas sssssssss eee 2 5 Rear Topper Window ne 2 2 Cargo Cover Soft Top sse 2 5 Side Topper Window n 2 2 Rolling Up the Side Panels 2 5 Sliding Rear Window ee 2 3 storing the Cargo COV6r iini dcectind eoe 2 5 Starting and Operating the Vehicle 2 3 Weapons Mount iere 2 7 Starting The Engine sssssssssssss 2 3 Weapons Mount Floor Mount 2 7 Weapons Mount Cab Mount ssss 2 8 Vehicle Load Disconnect Switch 2 4 2 1 Windows If the vehicle is equipped with a topper it features tempered opening windows that have locking handles Rear Topper Window Opening the Rear Window Door 1 Turn both handles A clockwise 90 2 Pull open the rear window door A cylinder on both sides of the window will assist with opening and hold the window in the open position Closing Rear Window Door 1 Pull the window door down 2 Turn both handles A counter clockwise 90 2 2 Notice The window must be fully closed before operation of the vehicle Side Topper Window Open the Side Window Doors 1 Turn both handles A clockwise 90 2 Pull open the window door
18. e manual and the page number where you ll find it Driving the Vehicle As with other vehicles of this type failure to operate this vehicle correctly may result in loss of control or an accident Refer to The Driving the Road and the Vehicle and Off Road Driving with The Four Wheel Drive Vehicle in the 2004 Vehicle Owner s Manual Safety Warnings and Symbols You will find a number of safety cautions in this book We use a box and the word CAUTION to tell you about things that could cause personal injury if you were to ignore the warning These mean there is something that could hurt you or other people In the caution area we tell you 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 be hurt Vehicle Damage Warnings Also in this supplement manual you will find notices Notice These mean there is something that could damage the vehicle In the notice area we tell you about something that can damage the vehicle Many times this damage would not be covered by the 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 ll also see warning labels on the vehicle They use the same words CAUTION or NOTICE NOTES Section 1 Seats and Restraints Troop S
19. eats neigen a e Eeee Eeee dares 1 2 Restraints oree adatta nik 1 3 Folding the Seat Down ssssssssssss 1 2 Rear Safety Strap ccce eene 1 3 Folding the Seat Up 1 3 1 1 Troop Seats If the vehicle is equipped with troop seats this feature provides space for up to eight passengers in the cargo area of the pickup model The seats can be lowered individually for use or raised for storage The seats lock in both the up and down positions Troop Seat Operation A quick release pin is located on the left or right side of the troop seat leg immediately under the hinge pin 1 2 When the seat is in the up position the quick release pin will go through the left hand leg for passenger s side seats or a right hand leg for driver s side seats It will then go through the seat channel and will be placed in front of the hinge pin Folding the Seat Down 1 Remove the pin and place the legs into the joint of the cargo area side and the floor Restraints Rear Safety Strap 2 Place the pin in the hole provided under the hinge pin The seat is now locked in the down position A Whenever the troop seats are occupied the safety strap Folding the Seat Up should be attached across the top of the rear seat backs Reverse Steps 1 and 2 using the eye bolts provided To remove the troop seats refer to Seats in the 2004 LSSV Military Trucks service manual supplement NOTES Section 2 Features an
20. f the needle is not in the green band the fuse may have blown If the fuse is not blown and the system still does not work properly refer to your local GM dealer Engine Off Reading In a no load situation with the engine off the gage needle should be mid way between the red band and green band in the yellow band If the gage needle is in the lower end of the yellow band this is unacceptable and the battery may be dead Section 4 Driving the Vehicle Your Driving the Road and the Vehicle 4 2 I ER EEE Using JP8 asa FUGIkuananananaraenn nanannamn 4 2 Towing the Vehicle Loading the Vehicle ssssssssssssss 4 2 Towing a Trailer 4 6 WINCH PEOVISIODS eoe ciencia ce eere reete pa d 4 2 Pintle Hiiessaare eine eite teda 4 7 If You Are Stuck In Sand Mud Ice or Snow 4 3 Trailer Wiring Connector esssssssss 4 8 Trailer Connector Adapter Tahoe Only 4 8 Your Driving the Road and the Vehicle Using JP8 as a Fuel Use of JP8 fuel is acceptable in Duramax 6 6L diesel vehicles and will not impact warranty coverage For additional information on other compatible fuels refer to the 2004 Duramax Diesel Engine Owner s Maunal Supplement Loading the Vehicle Do not load the vehicle any heavier than the GVWR or either the maximum front or rear GAWR If you do parts on the vehicle can
21. h a 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 vehicle s 12 pin connector Section 5 Service and Appearance Care Underhood Component Locator Silverado 5 2 Appearance Care mmmmumuuummmmmmmmmenmmuenemmn 5 14 Cleaning the Outside of the Vehicle 5 14 Underhood Component Locator Tahoe 5 3 Vehicle Information ssssssssssssss 5 15 Jump Starting itt erecti tete tied 5 4 Shipping Data Plate ssseeeeessss 5 15 Government Vehicle Data Plate 5 15 Vent Filters ssssssssssseeeem 5 11 Rear Axle Vent Tube Filter ssssssse 5 11 Electrical System eene 5 16 Transfer Case Vent Tube Filter 5 11 Fuses and Circuit Breaker sussuuse 5 16 Front Axle Vent Tube Filter ssssusse 5 11 Bulb Replacement esses 5 12 Replacement Bulbs ssssssssss 5 13 CIIM UL rer tere ee ET 5 13 Changing a Flat Tire 5 13 Inflation Tire Pressure sss 5 14 5 1 Underhood Component Locator Silverado ye EET Y a ne The following items are military options that may be found on the 6
22. he Soft Top Cargo Cover If the cargo cover has deteriorated replace it Refer to cargo cover replacement in the 2004 LSSV Military Trucks Service Manual Supplement The cargo cover is a waterproof welded plastic coated polyester Wash the cover 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 surface The windows should be washed with a water soaked cloth Do not rub dry Vehicle Information Shipping Data Plate K25903HD SHIPPING DATA PLATE 20710 TN 1935 0 A Dreux coro coros erro wor om ua D mer ts 2086 D Tom j 28992 4173 VOLUME IH XW X LI 234m The data plate is used to inform the operator of the vehicle as to the make model Gross Vehicle Weight GVW and vehicle dimensions It is located on the left corner of the left front inner door panel Government Vehicle Data Plate U S PROPERTY NOMENCLATURE TRUCK LSSV MCTL MAKE AND MODEL CHEV2500HDCK25903 MFRS VIN 1GCHK24133E321226 REGISTRATION NO N A CURB WEIGHT MAX PAYLOAD GVWR GCWR 6860 LBS 2340 LBS 9200 LBS 22000 LBS DATE OF DELIVERY 10 08 03 WARRANTY 36 MONTHS 36 000 MILES CONTRACT NO GS 3QF K0002 RPNNL5086 PART NO TX181623 The data plate is used to inform the operator of the vehicle as to the upfitting information and other spec
23. icle 1 Get the vehicles close enough so that jumper cables can reach but be sure the vehicles are not touching each other If they are it could cause a ground causing the 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 trans mission in PARK P Be sure the transfer case is in a drive gear and 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 required as well as radios This will avoid sparks and help save both batteries In addition it could save the radio Notice If you leave the communications navigation equipment on there is a risk that they could be badly damaged The repairs will not be covered by the warranty 3 Ensure the jumper cables do not have loose or missing insulation If they do you could get shocked and the vehicle could be damaged Before you connect the cables here are some basic things you should know Positive will go to positive Negative will go to a heavy unpainted metal engine part or a remote negative terminal if the vehicle has one 4 Open the hood and locate the battery Find the positive and negative terminals on each battery 5 5 Using a open
24. ifications It is located on the left front corner of the inner door panel 5 15 Electrical System Fuses and Circuit Breaker Circuit breakers protect the power accessories When the current load is too heavy the circuit breaker opens protecting the circuit until the problem is fixed Circuit Breaker Tahoe Only This circuit breaker is on the left rear fender support bracket of the engine compartment A 12 Volt Stud to Inverter B 24 Volt Stud to Inverter 5 16 The DC DC Inverter is located on the left rear panel of the cab The primary function of the DC DC Inverter is to provide 24V power The DC DC Inverter can deliver up to 40A of 24V current for applications such as two way radios navigations or the 24 volt battery Section 6 Maintenance Schedule Maintenance Schedule ssssssssss 6 2 Front Rear Axle Inspection 6 2 Transfer Case Inspection uuuussssss 6 2 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 equipped with an in line filter on the vent tubes Inspect the filters for blockages and replace as needed See Front Axle Vent Tube Filter and Rear Axle Vent Tube Filter in the Index for further information on the location of the front and rear axle filters Refe
25. le Inspection Transfer Case Vent Tube Filter The transfer case vent tube filter is located on the vent hose 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 See Transfer Case Inspection Front Axle Vent Tube Filter The front axle vent tube filter is located vent hose on the 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 See Front Rear Axle Inspection 5 11 Bulb Replacement Taillamps Maintenance Body A Turn Signal Lamp B Stoplamp C Back up Lamp 5 12 Using you hands peel the rubber seal away from the lens Lift the lens off the lamp assembly Pull the old bulb straight out from the socket Put a new bulb into the socket and press it in until it is tight Reinstall the lens and the lens seal Marker Lamps Maintenance Body Note The bulbs in the marker lamps are not replaceable and are serviced as an assembly 1 Using you hands peel the lens out of the rubber seal 2 Pull the wire connectors out from the back of the lens 3 Push the wire connectors into the new lens 4 Install the lens into the rubber seal Marker Lamps Blackout Note The bulbs in the blackout tail stop lamp and front marker lamps are light emitting diodes LED instead of incandescen
26. mps are also controlled by this switch Blackout Drive Light Control The switch located on the blackout switch panel next to the service light switch is the blackout drive light control The service lights blackout control switch must be in blackout position or in the down position for the blackout drive lights to function With the ignition switch in the ON position Pull the switch outward then up to the ON position the front blackout drive lamp will activate Pull the switch outward then down to the OFF position the blackout drive lamp will deactivate 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 Service Lights Blackout Switch Blackout Drive Light Switch Headlamps and Taillamps SERVICE ON OFF Parking Lamps SERVICE ON OFF Front Rear Side Marker Lamps SERVICE ON OFF Marker Lamps Roof Fender and End Gate SERVICE ON OFF Stop Lamps SERVICE ON OFF Back Up Lamps SERVICE ON OFF License Plate Lamps SERVICE ON OFF Front Rear Turn Signals SERVICE ON OFF Hazard Warning Lamps SERVICE ON ON OFF Cargo Lamp If Equipped SERVICE ON OFF Horn SERVICE ON OFF Front Rear Blackout Marker Lamps BLACKOUT ON OFF Blackout Stop Lamps BLACKOUT ON OFF Blackout Drive Lamp Headlamp BLACKOUT ON Exterior Lamp or Device Service Lights Blackout Switch Blackout Drive Light Switch Instrument Panel Swi
27. on other concerns 1 800 222 1020 Roadside Assistance Center towing and all Roadside 1 800 243 8872 Assistance program services Online Users You can find specific information on Service Parts After Sales Assistance GM Military History News Events Refer to the web for updated information www gm defense com Appearance CfE iisi siaina 5 14 Cleaning the Outside of the Vehicle 5 14 Cleaning the Soft Top Cargo Cover 5 14 B Blackout Drive Light Control sess 3 3 Bulb Replacement iiic 5 12 Cargo Cover Soft Top sees 2 5 Changing Flat Tre sisi ice ioc ee ces ce 5 13 Cleaning the Outside of the Vehicle 5 14 Cleaning the Soft Top Cargo Cover 5 14 Customer Assistance Information 7 2 Contact Information iiit 7 2 D Driving the Vehicle siib rie treten need iii Electrical SyStelm ucc oriatur rented eterne 5 16 Fuses and Circuit Breaker ssss 5 16 Circuit Breaker Tahoe Only 5 16 24 Volt Power Source Tahoe Only 5 16 Exterior Eamps c n eme 3 2 Service and Blackout Lighting 3 2 Service Lights Blackout Control 3 2 Blackout Drive Light Control
28. parasitic drain on the batteries Notice The main battery feeds to starter and NATO jump start connector remain powered The switch should be placed in the OFF position when the vehicle is parked for an extended period of time 12 VOLT 24 VOLT VEHICLE LOAD DISCONNECT SWITCH MAIN BATTERY FEEDS TO STARTER WINCH amp NATO JUMP START o CONNECTOR REMAIN POWERED z 9 5 This switch disconnects 12 volt vehicle loads amp 24 volt trailer aux loads that could cause parasitic drain on batteries Akje5343 Storage Areas Cargo Cover Soft Top If the vehicle is equipped with a soft top cargo cover it must be fully installed and properly anchored before traveling on the highway The side panels and rear panel of the cargo cover can be rolled up The cargo cover allows ventilation within the closed portion through opening vents located on the front of the top Rolling Up the Side Panels 1 Release tension on the hooks by pushing the release on the front of the hook 2 Remove the plastic hook from the bed fas tener 3 Pull apart the velcro flaps on both side panels near the vehicle cab 4 Pull apart the velcro flaps on both side panels near the back of the vehicle Roll the sides upward When the sides reach the top they can be held in place by inserting the cargo cover straps in the clips at the top of the cargo cover Storing the Cargo Cover 1 Release tension on the hooks by pushing the
29. r to Maintenance Schedule in the Index of the 2004 Vehicle Owner s Manual for additional maintenance information on the vehicle 6 2 Transfer Case Inspection Inspect the transfer case fluid level and add lubricant if necessary On manual shift transfer case oil 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 transfer case for kinks and proper installation See Transfer Case Vent Tube Filter in the Index for further information on the location of the filter Refer to Maintenance Schedule in the Index of the 2004 Vehicle Owner s Manual for additional maintenance information on the vehicle NOTES NOTES 6 4 Section 7 Customer Assistance Information Customer Assistance Information 7 2 Contact Information cccccseseceeeeeeeeeeeeeeeeeeees 7 2 7 1 Customer Assistance Information For customer assistance phone numbers refer to Contact Information To assist in our review of your concerns provide the following information The Vehicle Identification Number this will be on the VIN plate in the cab of the vehicle Current mileage on the vehicle Nature of the problem Contact Information Telephone Users Department Phone Number GM Customer Assistance Center general information dealer locati
30. ry or batteries installed in every 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 the eyes or on the 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 you unscrew the cover badly Keep your hands away from moving parts once the engine is running 5 10 Connect the slave cable to the vehicle with the dead battery Connect the slave cable to the vehicle with the good battery 6 Start the vehicle with the good battery 7 Allow the vehicle with the dead battery to charge for 10 minutes Note It may take up to 30 minutes to charge the battery enough to start the vehicle depending on the battery s 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 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 See Front Rear Ax
31. t bulbs They are not replaceable and are serviced as an assembly For bulb replacement refer to the 2004 LSSV Military Trucks Service Manual Supplement Replacement Bulbs Lamp Bulb Number Blackout Headlamp Topper Dome Lamp 24 Volt Gage Lamp License Plate Lamp Rear Turn Signal Lamp Back Up Lamp Tail and Stop Lamp o License Plate Lamp Maintenance Body Models For bulbs not listed here refer to the 2004 Vehicle Owner s Manual Tires Changi ng a Flat Tire The military heavy duty bumper of the vehicle has an opening A to gain access to the spare tire hoist For more information refer to Changing a Flat Tire in the Index of the 2004 Vehicle Owner s Manual 5 13 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 Index of the 2004 Vehicle 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 14 Cleaning t
32. tch Illumination SERVICE ON OFF Radio Clock Illumination SERVICE ON OFF Headlamp High Beam Indicator SERVICE ON OFF Turn Signal Hazard Warning Indicators SERVICE ON OFF Four Wheel Drive Indicator SERVICE ON ON Dome Courtesy Lamps SERVICE ON OFF Glove Compartment Lamp SERVICE ON OFF Warning Chime Headlamps On SERVICE ON ON OFF Instrument Cluster Warning Lights 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 controlled by a master switch on the side of the dome lamp and a pair of 3 way switches The bed mounted 3 way switch A is located in the left rear of the cargo bed The interior 3 way switch A is located on the blackout switch panel 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 The interior mounted 3 way switch will not function The bed mounted 3 way switch will not function The dome lamp will not function in the blackout mode Warning Lights Gages and Indicators 24 Volt Gage The 24 volt gage is located in the instrument panel next to the service and blackout lighting switch Engine Running Reading The gage needle should be in the green band when engine speed is above an idle I
33. this mount The floor mount weapon mount is located behind the front seats and will secure two weapons 1 Place the stock of the weapon into the lower mount 2 Place the barrel into the upper mount until fully seated in the clamp 3 Secure with strap and pull to tighten Pull the strap outward and slide it over the barrel of the weapon and secure the buckle by pulling tight 2 7 Weapon Mount Cab Mount Lower Weapon Mount The cab mounted weapon mounts are located at the To secure weapons in the vehicle s mount rear of the cab and will secure one weapon each 1 Place the stock into the lower weapon mount N CAUTION LS 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 Upper Weapon Mount 2 Place the barrel into the upper weapon mount until fully seated 3 Pull the strap outward and slide it over the barrel of the weapon and secure the buckle by pulling tight Section 3 Instrument Panel Exterior Lamps ne tdv eei ies 3 2 Interior Lamps neri hess 3 6 Service and Blackout Lighting 3 2 Topper Dome Lamp rrrnnvvnnnrvrnnsnvvrrnsnvrrsnvvnnnsnvvrrnvnnn 3 6 Operating Service and Blackout Lighting 3 4 Warning Lights Gages and Indicators 3 7
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