Page 3: For Canadian Owners Who Prefer A French Language Manual
We support voluntary technician certification. GENERAL MOTORS, GM, the GM Emblem, GMC and the GMC Truck Emblem are registered trademarks of General Motors Corporation. This manual includes the latest information at the time it was printed. We reserve the right to make changes For Canadian Owners Who Prefer a after that time without further notice.
Page 4: How To Use This Manual
How to Use this Manual CAUTION: Many people read their owner’s manual from beginning to end when they first receive their new vehicle. If you do this, it will help you learn about the features These mean there is something that could hurt and controls for your vehicle.
Page 5: Vehicle Damage Warnings
Vehicle Damage Warnings Vehicle Symbols Also, in this book you will find these notices: Your vehicle may be equipped with components and labels that use symbols instead of text. Symbols, used on your vehicle, are shown along with the text describing the operation or information relating to a NOTICE: specific component, control, message, gage or indicator.
Page 6 These are some examples of vehicle symbols you may find on your vehicle:...
Page 7: Model Reference
Model Reference C7H064 This manual contains information which covers conventional cab models as shown. Most models are unfinished from the factory. C6H042 C7H042 Since C-Series models delivered from the factory are finished in a variety of ways by a number of companies, you’ll probably find other manuals in your finished vehicle.
Page 8: Section 1 Seats And Restraint Systems
Section 1 Seats and Restraint Systems Here you’ll find information about the seats in your vehicle and how to use your safety belts properly. You can also learn about some things you should not do with safety belts. Seats and Seat Controls Center Passenger Position Safety Belts: They’re for Everyone Children...
Page 9: Seats And Seat Controls
Seats and Seat Controls Bucket and Bench Seats This section tells you about the seats in your vehicle and how to adjust them. CAUTION: You can lose control of the vehicle if you try to adjust the seat while the vehicle is moving. The sudden movement could startle and confuse you, or make you push a pedal when you don’t want to.
Page 10: Head Restraints
Head Restraints Seatback Latches The full width bench seat seatback folds forward to let you reach the rear of the cab. Bucket seats have outboard mounted levers to tilt the seatbacks forward or rearward. Your seatback will move back and forth freely unless you come to a sudden stop then it will lock into place.
Page 11 To return the seatback to its original position, push National Seats (If Equipped) the seatback toward the rear of the vehicle. Push and pull the seatback to be sure it’s locked into place. The latch must be down for the seat to work properly.
Page 12 Height Adjustment To adjust the height of the cushion, lift the cushion To adjust the height of height adjustment handle a self contained seat up and forward. You can (hand pumped air seat), choose between two push the seat height settings.
Page 13 Seatback Adjustment Chugger Snubber Lock Out Feature (If Equipped) To tilt the seatback, turn If your vehicle has this the backrest tilt knob. feature, the handle is The knob is located on located on the lower the lower cushion, on the outboard side of the outboard side of the driver’s driver’s seat and the...
Page 14: Safety Belts: They're For Everyone
Safety Belts: They’re for Everyone CAUTION: This part of the manual tells you how to use safety belts properly. It also tells you some things you should not do with safety belts. It is extremely dangerous to ride in a cargo area, inside or outside of a vehicle.
Page 15: Why Safety Belts Work
If your vehicle has a safety belt reminder tone, a tone Why Safety Belts Work comes on as a reminder to buckle up. See “Safety Belt Aren’t safety belts for kids? Reminder Tone” in the Index. In most states and Canadian provinces, the law says to Yes.
Page 16 If the vehicle hits something, it stops right then. Then something will stop them. It could be the windshield. But nothing stops the people. They keep moving.
Page 17 Or it could be the instrument panel. With belts, you slow down as the vehicle does. You get more time to stop. Now, what if you and your passengers were to give that big vehicle a chance to deal with the force of the impact, You stop over more distance, and your strongest bones instead of you? take the forces.
Page 18: Here Are Questions Many People Ask
Here Are Questions Many People Ask If I’m a good driver, and I never drive far from home, why should I wear safety belts? About Safety Belts and the Answers You may be an excellent driver, but if you’re in an Won’t I be trapped in the vehicle after an accident even one that isn’t your fault...
Page 19: How To Wear Safety Belts Properly
How to Wear Safety Belts Properly Lap-Shoulder Belt The driver has a lap shoulder belt. Here’s how to Adults wear it properly. This part is only for people of adult size. 1. Close and lock the door. Be aware that there are special things to know about safety 2.
Page 20 If the belt isn’t long enough, see “Safety Belt Extender” at the end of this section. Make sure the release button on the buckle is positioned so you would be able to unbuckle the safety belt quickly if you ever had to. Suspension (B) 3.
Page 21 If the shoulder belt is too tight: Let it go back all the way. Pull out the belt at least 5 inches (130 mm). 1-14...
Page 22 You can add a small amount of slack. The system The lap part of the belt should be worn low and snug on works like a window shade. To add a little slack, the hips, just touching the thighs. In a crash, this applies pull down on the shoulder belt just a little no more force to the strong pelvic bones.
Page 23 What’s wrong with this? CAUTION: You can be seriously hurt if your shoulder belt is too loose. In a crash, you would move forward too much, which could increase injury. The shoulder belt should fit against your body. Don’t allow more than 1 inch (25 mm) of slack. The shoulder belt is too loose.
Page 24 What’s wrong with this? CAUTION: You can be seriously injured if your belt is buckled in the wrong place like this. In a crash, the belt would go up over your abdomen. The belt forces would be there, not at the pelvic bones. This could cause serious internal injuries.
Page 25 What’s wrong with this? CAUTION: You can be seriously injured if you wear the shoulder belt under your arm. In a crash, your body would move too far forward, which would increase the chance of head and neck injury. Also, the belt would apply too much force to the ribs, which aren’t as strong as shoulder bones.
Page 26 What’s wrong with this? CAUTION: You can be seriously injured by a twisted belt. In a crash, you wouldn’t have the full width of the belt to spread impact forces. If a belt is twisted, make it straight so it can work properly, or ask your dealer to fix it.
Page 27 Bench (A) Suspension (B) To unlatch the belt, just push the button on the buckle. The belt should go back out of the way. For a suspension type seat, if the belt is pulled out all the way so that it locks, press down on the button on the retractor cover to make it retract.
Page 28: Safety Belt Use During Pregnancy
Safety Belt Use During Pregnancy A pregnant woman should wear a lap shoulder belt, and the lap portion should be worn as low as possible, Safety belts work for everyone, including pregnant below the rounding, throughout the pregnancy. women. Like all occupants, they are more likely to be The best way to protect the fetus is to protect seriously injured if they don’t wear safety belts.
Page 29: Center Passenger Position
Center Passenger Position Lap Belt If your vehicle has a full bench seat or a two passenger bench seat, someone can sit in the center position. When you sit in a center seating position, you have a lap safety belt, which has no retractor. To make the belt longer, tilt the latch plate and pull it along the belt.
Page 30: Infants And Young Children
Children Everyone in a vehicle needs protection! This includes infants and all other children. Neither the distance traveled nor the age and size of the traveler changes the need, for everyone, to use safety restraints. In fact, the law in every state in the United States and in every Canadian province says children up to some age must be restrained while in a vehicle.
Page 31 CAUTION: (Continued) For example, in a crash at only 25 mph (40 km/h), a 12 lb. (5.5 kg) baby will suddenly become a lb. (110 kg) force on a person’s arms. A baby should be secured in an appropriate restraint. CAUTION: People should never hold a baby in their arms while riding in a vehicle.
Page 32 What are the different types of add child restraints? CAUTION: on child restraints, which are purchased by the vehicle’s owner, are available in four basic Newborn infants need complete support, types. Selection of a particular restraint should including support for the head and neck. This is necessary because a newborn infant’s take into consideration not only the child’s weight, neck is weak and its head weighs so much...
Page 33 We know securing a child can present real problems in a medium duty vehicle like yours. The only place where CAUTION: you can properly secure a child restraint is the center seating position, the place that has the lap belt only. The body structure of a young child is quite But your vehicle may not have a center seating position.
Page 34: Restraint Systems For Children
Restraint Systems for Children A rear facing infant seat (B) provides restraint with the seating surface against the back of the infant. The harness system holds the infant in place and, in a An infant car bed (A), a special bed made for use in a motor vehicle, is an infant restraint system designed to crash, acts to keep the infant positioned in the restraint.
Page 35 A forward facing child seat (C E) provides restraint for A booster seat (F G) is a child restraint designed to the child’s body with the harness and also sometimes improve the fit of the vehicle’s safety belt system. with surfaces such as T shaped or shelf like shields.
Page 36 How do child restraints work? When choosing a child restraint, be sure the child restraint is designed to be used in a vehicle. If it is, A child restraint system is any device designed for it will have a label saying that it meets federal motor use in a motor vehicle to restrain, seat, or position vehicle safety standards.
Page 37: Top Strap
Top Strap Some child restraints have a top strap, or “top tether.” It can help restrain the child restraint during a collision. For it to work, a top strap must be properly anchored to the vehicle. Some top strap equipped child restraints are designed for use with or without the top strap being anchored.
Page 38 Securing a Child Restraint in the Center Seat Position (Full Bench Seat and Two-Passenger Bench Seat) You’ll be using the lap belt. Be sure to follow the instructions that came with the child restraint. Secure the 1. Make the belt as long as possible by tilting the latch child in the child restraint when and as the instructions plate and pulling it along the belt.
Page 39 4. Buckle the belt. Make sure the release button is positioned so you would be able to unbuckle the safety belt quickly if you ever had to. 5. To tighten the belt, pull its free end while you push down on the child restraint. If you’re using a forward facing child restraint, you may find it helpful to use your knee to push down on the child...
Page 40: Older Children
Older Children What is the proper way to wear safety belts? If possible, an older child should wear a shoulder belt and get the additional restraint a shoulder belt can provide. The shoulder belt should not cross the face or neck. The lap belt should fit snugly below the hips, just touching the top of the thighs.
Page 41 CAUTION: Never do this. Here two children are wearing the same belt. The belt can’t properly spread the impact forces. In a crash, the two children can be crushed together and seriously injured. A belt must be used by only one person at a time. What if a child is wearing a lap shoulder belt, but the child is so small that the shoulder belt is...
Page 42 CAUTION: Never do this. Here a child is sitting in a seat that has a shoulder belt, but the shoulder part is behind the child. If the child wears the belt in this way, in a crash the child might slide under the belt. The belt’s force would then be applied right on the child’s abdomen.
Page 43: Safety Belt Extender
Safety Belt Extender Replacing Restraint System Parts After a Crash If the vehicle’s safety belt will fasten around you, you should use it. If you’ve had a crash, do you need new belts? But if a safety belt isn’t long enough to fasten, your After a very minor collision, nothing may be necessary.
Page 44: Section 2 Features And Controls
Section 2 Features and Controls Here you can learn about the many standard and optional features on your vehicle, and information on starting, shifting and braking. Also explained are the instrument panel and the warning systems that tell you if everything is working properly and what to do if you have a problem.
Page 45 Windows CAUTION: Leaving children in a vehicle with the windows closed is dangerous. A child can be overcome by the extreme heat and can suffer permanent injuries or even death from heat stroke. Never leave a child alone in a vehicle, especially with the windows closed in warm or hot weather.
Page 46: Manual Windows
Manual Windows Turn the hand crank on each door to raise or lower the window. Power Windows (If Equipped) If you have power windows, the controls are located on each door. The driver’s door has a switch for the passenger’s window as well. Your power windows will not move unless the ignition switch is turned to ON.
Page 47 Keys CAUTION: Leaving children in a vehicle with the ignition key is dangerous for many reasons. A child or others could be badly injured or even killed. They could operate the power windows or other controls or even make the vehicle move. Don’t leave the keys in a vehicle with children.
Page 48 The square head key is for If you have the optional one key system, the oval key the ignition switch only. will operate all locks, including the ignition switch. When a new vehicle is delivered, the dealer removes the plugs from the keys and gives them to the first owner. Each plug has a code on it that tells your dealer or a qualified locksmith how to make extra keys.
Page 49: Door Locks
Door Locks The manual door locks are located on both the driver’s and passenger’s doors. CAUTION: Unlocked doors can be dangerous. Passengers especially children easily open the doors and fall out of a moving vehicle. When a door is locked, the handle won’t open it.
Page 50: Power Door Locks - If Equipped
Power Door Locks (If Equipped) Theft Vehicle theft is big business, especially in some cities, If your vehicle has this and even commercial vehicles are no exception. feature, the controls will be Although your vehicle has a number of theft deterrent located on both the driver’s features, we know that nothing we put on it can make...
Page 51 New Vehicle “Break In” NOTICE: (Continued) Avoid making hard stops for the first NOTICE: 200 miles (322 km) or so. During this time your new brake linings aren’t yet broken Your vehicle doesn’t need an elaborate in. Hard stops with new linings can mean “break in.”...
Page 52: Ignition Positions
Ignition Positions Engine Starter Over Crank Protection (If Equipped) Use your ignition key to start your vehicle. You can Some vehicles have an engine starter over crank turn the ignition switch to protection system. This system includes a built four different positions. temperature limiting switch to prevent internal damage to the starter.
Page 53: Manual Transmission
Manual Transmission Starting Your Engine Set the parking brake, shift to neutral and hold the clutch 1. Without pushing the accelerator pedal, turn your pedal to the floor while starting the engine. ignition key to START. When the engine starts, let go of the key.
Page 54 Restarting the Gasoline Engine While NOTICE: Moving (Automatic Transmission) If you have to restart the engine while the vehicle is Your engine is designed to work with the moving, you’ll first have to shift the automatic electronics in your vehicle. If you add electrical transmission to NEUTRAL (N).
Page 55: Starting The Diesel Engine
Starting the Diesel Engine Restarting the Diesel Engine While Moving (Automatic Transmission) If you have a Caterpillar diesel engine, also refer to your Caterpillar Diesel Engine Operation & Maintenance If you have to restart the engine while the vehicle is Manual for starting procedure.
Page 56 Cold Weather Starting Diesel Engine Warm-Up (Caterpillar Diesel) Several factors affect how quickly your diesel engine warms up. These can include outside temperature, Because the diesel engine uses compression ignition, it engine load, idle time and your vehicle’s option content. is harder to start in cold weather than a gasoline engine.
Page 57: Fast Idle System
Engine Alarm and Automatic Fast Idle System (Electronically Controlled Shutdown (Option) Caterpillar Diesel and Gasoline Engines) Your CHECK GAGES light will come on if the system Your vehicle is equipped with an electronically senses high engine temperature or low engine oil controlled diesel engine.
Page 58 Manual Fast Idle System (Caterpillar Diesel and The manual transmission (if equipped) clutch Gasoline Engines) pedal is not pressed or, the automatic transmission (if equipped) is in NEUTRAL (N). The manual fast idle switch The manual fast idle feature is activated by pressing the is located on the lower switch on the instrument panel.
Page 59: Engine Checks Before Operating
Radiator Shutters -- Caterpillar If the engine coolant temperature gage needle goes into the hot area on the gage, stop the engine and (If Equipped) find the cause of the overheating. Radiator shutters aid engine warm up by blocking the If you have air brakes, the dual needle air pressure airflow through the radiator and charge air cooler to...
Page 60: Engine Coolant Heater (If Equipped)
The voltmeter charge indicator gage tells you the Engine Coolant Heater (If Equipped) condition of your battery’s charge. The gage should be in the center area during engine operation. The If your vehicle is equipped red area on the left indicates an undercharge with this feature, the condition;...
Page 61: To Use The Engine Coolant Heater
To Use the Engine Coolant Heater 4. Before starting the engine, be sure to unplug the cord. 1. Turn off the engine. How long should you keep the coolant heater plugged 2. Find the plug in receptacle (either behind the front in? The answer depends on the outside temperature.
Page 62 The switch is located on Do not use the exhaust brake when running the engine the upper right side of at idle during warm up or other extended periods. the instrument panel and Prolonged use of the exhaust brake during idling will turns the exhaust brake cause the engine to overheat.
Page 63 Speed Rear Axle Electric Shift When the knob is up, the rear axle is in the high range. Push it down to get the low range. Control (If Equipped) The two speed axle should be in low range when you If your vehicle is equipped with this feature, you’ll find park the vehicle.
Page 64: Manual Transmission
Manual Transmission Air Shift Control (Manual Transmissions Only) The knob for the rear axle shift control is on the The lever for the rear axle shift lever. shift control is either at the lower right corner of the instrument panel or on the shift lever.
Page 65: Air Suspension (If Equipped)
Also, always start the vehicle in motion with the Air Suspension Dump Control (If Equipped) speed axle in the LOW position. When you upshift If your vehicle is equipped with the Hendrickson the rear axle from LOW to HI, move the lever to the HI HAS Series single axle air suspension, you may have position, disengage the clutch, pause, engage the clutch...
Page 66: Automatic Transmission Operation
Automatic Transmission Operation CAUTION: We build vehicles with four, five and six speed automatic transmissions. This part of the manual covers It is dangerous to get out of your vehicle if the the basics of these. With some of the transmissions, you shift lever is not fully in PARK (P) with the will find another manual in your vehicle that goes into more detail.
Page 67: Manual Transmission Operation
Automatic Transmission Third Gear Hold Eaton Fuller 5 and 6-Speed Transmissions (If Equipped) and TTC Spicer 7-Speed Transmissions If your vehicle is equipped with this feature, your range These transmissions have gears that automatically selector has a 2 3 position. You can’t shift up to the synchronize when you shift up or down (except next higher gear when the transmission is in this FIRST (1) gear on the five...
Page 68 Eaton Fuller 9 and 10-Speed Double-Clutching Non-Synchronized Manual Transmissions You must use the double clutching method when you (If Equipped) shift an unsynchronized gear set. Disengage the clutch, shift to neutral and engage the clutch. When upshifting, If your vehicle has one of these unsynchronized slow the engine until the engine rpm and road speed transmissions, it’s naturally somewhat complicated.
Page 69: Two-Speed Rear Axle
Clutch Brake (Vehicles with Parking Non-Synchronized Transmission) A clutch brake is used to stop transmission input shaft CAUTION: rotation so that FIRST (1) or REVERSE (R) gear selection can be initiated when the vehicle is at a standstill and the engine is idling. If you don’t park your vehicle properly, it can roll.
Page 70: Hydraulic Brakes (If Equipped)
Hydraulic Brakes (If Equipped) Propshaft Brake Burnish Procedure If your vehicle has hydraulic brakes, it has a parking It is recommended that the propshaft mounted parking brake lever or an electric/hydraulic parking brake. The brake be burnished as part of the new vehicle break lever is located below the instrument panel to the left of The parking brake will work best after it has been the steering column.
Page 71 Lever Operated Parking Brake To release the parking brake, first push down the To apply the parking brake, regular brake pedal. Then, pull the lever all the way up. push the parking brake lever The PARK BRAKE light all the way down and shift will come on when the the automatic transmission parking brake is applied.
Page 72 Electric/Hydraulic Parking Brake If your vehicle has this system, you will have a (If Equipped) knob located to the right of the steering column. CAUTION: It will take a few seconds for the parking brake to fully apply, and even longer when it is cold outside.
Page 73 Air Brake (If Equipped) If your vehicle has air brakes, you will have this control. Pulling it out applies the parking brake. CAUTION: The PARK BRAKE light will come on when the air When the yellow SYSTEM PARK and the red parking brake is applied.
Page 74 Vehicles built for use as tractors or towing vehicles have 3. Get into the tractor. Push and hold down the regular one or two more air brake controls. They look like this: brake pedal. 4. Push in both the yellow SYSTEM PARK and the red TRAILER AIR SUPPLY knobs.
Page 75 CAUTION: CAUTION: If you apply any one of the air brake parking If your vehicle is left in gear, the engine can controls while the vehicle is moving, your rig will start if the vehicle starts to roll. This can easily stop suddenly.
Page 76: Parking Over Things That Burn
Parking Over Things That Burn Engine Exhaust CAUTION: Engine exhaust can kill. It contains the gas carbon monoxide (CO), which you can’t see or smell. It can cause unconsciousness and death. You might have exhaust coming in if: Your exhaust system sounds strange or different.
Page 77: Running Your Engine While You're Parked (Automatic Transmission)
Running Your Engine While You’re CAUTION: Parked (Automatic Transmission) It’s better not to park with the engine running. But if you It can be dangerous to get out of your vehicle if ever have to, here are some things to know. the shift lever is not fully in PARK (P) with the parking brake firmly set.
Page 78: Tilt Wheel (If Equipped)
Tilt Wheel (If Equipped) CAUTION: A tilt wheel allows you to adjust the steering wheel before you drive. You can raise it to the highest level to give your legs more room when you exit and enter It can be dangerous to get out of your vehicle your vehicle.
Page 79: Turn Signal/Multifunction Lever
Turn Signal/Multifunction Lever Turn and Lane-Change Signals The turn signal has two upward (for right) and two downward (for left) positions. These positions allow you to signal a turn or a lane change. To signal a turn, move the lever all the way up or down. When the turn is finished, the lever will return automatically.
Page 80 Signal Stat Turn Signal and Hazard Warning To signal a turn, move the lever all the way up or down. Flasher (If Equipped) When the turn is completed, move the lever back to the center position. If you have this signal system, it is mounted beside or behind the multifunction lever on the left side of the An arrow on the instrument panel cluster will flash in steering column.
Page 81: Headlamp High/Low-Beam Changer
Headlamp High/Low-Beam Changer Windshield Wipers To change the headlamps from low to high beam or high to low beam, pull the multifunction lever all the way toward you, then release it. When the high beams are on, this light on the instrument panel cluster will also be on.
Page 82: Windshield Washer
Low Speed Delay Wipers (If Equipped) Windshield Washer At the top of the multifunction lever, there’s a paddle You can set the wiper speed with the word PUSH on it. To spray washer fluid on the for a long or short delay windshield, push the paddle.
Page 83: Cruise Control (If Equipped)
Cruise Control (If Equipped) If you have a manual transmission and you apply your brakes or push the clutch pedal, the cruise control will If your vehicle has this shut off. feature, it is located at the end of the turn signal/multifunction lever.
Page 84 Setting Cruise Control Resuming a Set Speed Once you’re going about 30 mph (48 km/h) or more, you can move the cruise control switch from ON to CAUTION: R/A (Resume/Accelerate) briefly. The vehicle will return to your chosen speed and If you leave your cruise control switch on when stay there.
Page 85 Increasing Speed While Using Cruise Control Reducing Speed While Using Cruise Control There are two ways to go to a higher speed: Press in the button at the end of the lever until you reach the lower speed you want, then release it. Use the accelerator pedal to get to the higher speed.
Page 86 Using Cruise Control on Hills Ending Cruise Control How well your cruise control will work on hills depends There are different ways to turn off the cruise control: upon your speed, load and the steepness of the hills. Step lightly on the brake pedal. When going up steep hills, you may want to step on the Push the clutch pedal, if you have a accelerator pedal to maintain your speed.
Page 87 Trailer Brake Hand Control This feature lets you apply the trailer brakes without applying the tractor brakes. You can apply the trailer Valve (Option) brakes a little or apply them all the way if you have to. Use this control only when you’re driving. Don’t use it If your vehicle has this feature, the control is mounted for parking or to hold the rig on a hill.
Page 88 Inter Axle Differential Lock Control NOTICE: (If Equipped) Activating the inter axle differential lock when If your vehicle has this feature, the control is the rear wheels are actually spinning freely, as located at the lower they might on ice or snow, can cause you to lose right corner of the control of the vehicle.
Page 89: Rear Axle Differential Lock Control
Rear Axle Differential Lock Control If you’re approaching a slippery surface where it looks like one or even both wheels may start to slip, you can (If Equipped) use this control. It locks your rear differential so that power is transmitted equally to both rear wheels. If your vehicle has a controlled traction or Let up on the accelerator before you turn on your rear...
Page 90 Engine Air Control (If Equipped) When the handle is pulled out, the engine air intake supply is closed off from the front scoop and an under hood air supply is opened. This control is intended only for use in cold weather (32 _ F (0 _ C) or below) where snow and ice might plug the external intake.
Page 91: Exterior Lamps
Exterior Lamps The exterior lamp switches located on the left side of your instrument panel cluster operate the exterior lamps. (Off): Press this switch to turn off all lamps, except the Daytime Running Lamps (DRL). (Parking Lamps): Press this switch to turn on the parking lamps, together with the following: Marker Lamps (if your vehicle has the marker and clearance lamps switch)
Page 92: Daytime Running Lamps
Headlamps On Reminder (If Equipped) When the DRL are on, only your low beam headlamps will be on. The exterior lamps won’t be on. Your If you have this system, a tone alarm will sound when instrument panel won’t be lit up either. your headlamps and/or parking lamps are turned on and When it begins to get dark, your DRL indicator light is your ignition is in LOCK or ACC.
Page 93 Marker and Clearance Lamps Switch (If Equipped) Your vehicle will have this switch only if it is designed to pull a trailer. If it has this switch, you’ll find it located on the upper right side of your instrument panel, just above the radio.
Page 94: Interior Lamps
Interior Lamps Outside Mirrors Adjust the outside mirror or Instrument Panel Brightness Control mirrors by hand so you can This feature controls the brightness of the instrument just see a little of the side of panel lights. your vehicle when you’re sitting in the driver’s seat.
Page 95: Heated Outside Mirrors (If Equipped)
Convex Outside Mirrors (Option) Heated Outside Mirrors (If Equipped) Your vehicle may have optional convex mirrors. A If your vehicle has heated convex mirror’s surface is curved so you can see more mirrors, you’ll find this from the driver’s seat. switch on the upper right side of your instrument panel area, just above the...
Page 96: Sun Visors
Ashtray and Cigarette Lighter NOTICE: (If Equipped) The ashtray is located below the gages on the right side Don’t put papers and other things that burn into of your instrument panel. If you have a cigarette lighter, your ashtray. If you do, cigarettes or other it is inside the ashtray.
Page 97 Auxiliary Power Jacks (If Equipped) NOTICE: These jacks provide 12 volt power so you can operate things such as a citizen’s band (CB) radio Whether or not your vehicle has the power or a cellular phone. outlets, don’t plug in FM communications gear If your vehicle has these at the ashtray area.
Page 98: Air Connections
Trailer Connections (If Equipped) Electrical Connections This system has a seven wire cable that will go to the If your vehicle has these connections, they are located at trailer to supply electrical power to the trailer’s lighting the rear of the cab. There is an air connection and a system.
Page 99 The Instrument Panel Your Information System 2-56...
Page 100 The main components of your instrument panel are the following: A. Left Side Window Defogger J. Glove Box B. Exterior Lamps Switch K. Hourmeter (If Equipped) C. Vent L. Convenience Center Fuse Panel D. Instrument Panel Cluster M. Air Vent Controls E.
Page 101: Instrument Panel Cluster
Instrument Panel Cluster Your instrument panel cluster is designed to let you know at a glance how your vehicle is running. You’ll know how fast you’re going, about how much fuel is left and many other things you’ll need to drive safely and economically. Gasoline Engine Shown;...
Page 102: Speedometer And Odometer
Speedometer and Odometer You may wonder what happens if your vehicle needs a new odometer installed. If the new one can be set to the mileage total of the old odometer, then it must be. But if it can’t, then it’s set at zero, and a label must be put on the driver’s door to show the old mileage reading when the new odometer was installed.
Page 103: Tachometer (If Equipped)
Tachometer (If Equipped) Warning Lights, Gages and Indicators This part describes the warning lights and gages may be on your vehicle. The pictures will help you locate them. Warning lights and gages can signal that something is wrong before it becomes serious enough to cause an expensive repair or replacement.
Page 104 When one of the warning lights comes on and stays on Charging System Indicator Light when you are driving, or when one of the gages shows there may be a problem, check the section that tells you what to do about it. Please follow this manual’s advice. CAUTION: Waiting to do repairs can be costly and even...
Page 105 If it stays on, or comes on while you are driving, have it Readings in either warning zone indicate a possible checked right away. You could have a loose generator problem in the electrical system. drive belt or some other problem. Readings in the low warning zone may occur when a Driving while this light is on could drain your battery.
Page 106 Check Transmission Warning Light NOTICE: (If Equipped) If your vehicle has the If the check transmission warning light comes on Allison MD automatic while you are driving, it is a warning that making transmission, certain a transmission “range” change could leave you transmission malfunctions stranded.
Page 107: Brake System Warning Light
Range Inhibited Warning Light Brake System Warning Light (If Equipped) Your vehicle has either hydraulic or air brakes. Each system has different warning lights. If your vehicle is equipped with an Allison automatic Hydraulic Brake System Warning Lights transmission, this light Vehicles with hydraulic systems have two brake system could turn on indicating that warning lights on the instrument panel.
Page 108 If the AUX BRAKE If one or both of these lights come on and stay on while warning light comes on, it you are driving, pull off the road and stop carefully. You means that there is may notice that the pedal is harder to push. Or, the pedal something wrong in the may go closer to the floor.
Page 109 Air Brake System Warning Light CAUTION: Vehicles with air brake systems have one brake system warning light on the instrument panel. If the LOW AIR warning light comes on and the The LOW AIR warning warning tone sounds, the vehicle can stop light should come on, as a suddenly and without further warning.
Page 110: Parking Brake Warning Light
Apply Park Brake Warning Light (Option) Parking Brake Warning Light This light warns the driver This light turns on as a that the ignition has been check when the engine is turned off without applying first started and any time the the parking brake.
Page 111: Anti-Lock Brake System Warning Light
Parking Brake Indicator Light Anti-Lock Brake System Warning Light Vehicles with hydraulic or With the anti lock brake air brakes have a brake system, this light will come indicator light. When the on when you start your ignition is on, this light will engine and it may stay come on when you set your on for several seconds.
Page 112: Trailer Anti-Lock Brake System Warning Light
Trailer Anti-Lock Brake System Engine Coolant Temperature Gage Warning Light If your vehicle is connected to an anti lock brake system equipped trailer, this light should come on briefly, as a check, when you turn on the ignition. When this light comes on and stays on, it means there is Gasoline Engine Diesel Engine something wrong in the trailer anti...
Page 113: Low Coolant Warning Light
Low Coolant Warning Light Manual Fast Idle Indicator Light (If Equipped) You have a LOW COOLANT warning If your vehicle is equipped light. If this light comes with an electronically on, your system is low controlled diesel engine or on coolant and the engine gasoline engine, you may may overheat.
Page 114: Diesel Engines
Intake Heater Indicator Light Service Transmission Filter Indicator Light (Diesel Engines) (If Equipped) This light on the instrument If your vehicle has this panel cluster will come light, you’ll find it located on when the intake heater below the the instrument is on and the ignition key panel cluster.
Page 115: Malfunction Indicator Lamp (Check Engine Light)
Malfunction Indicator Lamp This light should come on when the ignition is on, but the engine is not running, as a check to show you it is (Check Engine Light) working. If it does not come on at all, have it repaired. If your vehicle is equipped with either a gasoline engine or an electronically controlled diesel engine, you will NOTICE:...
Page 116: Engine Oil Pressure Gage
Engine Oil Pressure Gage A reading in the low pressure zone may be caused by a dangerously low oil level or other problem. If you have a Caterpillar diesel engine, also see your Caterpillar Operation & Maintenance Manual. CAUTION: Don’t keep driving if the oil pressure is low. If you do, your engine can become so hot that it catches fire.
Page 117 Change Oil Light (If Equipped) Reduced Engine Power Warning Light The CHANGE OIL light If the CHECK ENGINE should come on briefly and REDUCED ENGINE as a bulb check when you POWER lights are on, a start the engine. If the noticeable reduction in light doesn’t come on, the vehicle’s performance...
Page 118: Differential Lock Indicator Light
Differential Lock Indicator Light Transmission Temperature Gage (Option) (If Equipped) If you have an automatic transmission equipped with This light located on the this gage, it is located to the instrument panel cluster is right of the dash mounted on when the inter axle shift lever.
Page 119: Daytime Running Lamps (Drl) Indicator Light
Daytime Running Lamps (DRL) When the CHECK GAGES light comes on, you will also hear a warning tone. The tone and the light will stay Indicator Light activated until the problem is corrected. This light is located on This light may also come on if your vehicle is equipped the upper portion of the with the optional automatic engine shutdown system and instrument panel cluster.
Page 120 When the ignition is on, your fuel gage lets you know Air Pressure Gage (If Equipped) about how much fuel you have left. When the gage first If your vehicle has air shows empty, you’ll still have a little fuel left, but you brakes, this gage at the should get more fuel soon.
Page 121 Filter Minder Gage Hourmeter Gage (If Equipped) (Diesel Engine) (Option) If your vehicle has this gage, it will be to the lower This optional gage is in left of the steering column, the lower center of the mounted on a bracket either instrument panel cluster.
Page 122: Section 3 Comfort Controls And Audio Systems
Section 3 Comfort Controls and Audio Systems In this section, you’ll find out how to operate the comfort control and audio systems offered with your vehicle. Be sure to read about the particular systems supplied with your vehicle. Comfort Controls AM/FM Stereo Air Conditioning Remote Cassette Tape Player (If Equipped)
Page 123: Comfort Controls
Comfort Controls (Floor): This setting sends most of the airflow through the floor outlets. The rest of the air flows Standard Comfort Controls through the windshield and side window vents. If your vehicle does not have air conditioning, this is (Defog): This setting divides the airflow between what your comfort controls will look like.
Page 124 Optional Comfort Controls (If Equipped) If your vehicle has air conditioning, your comfort controls will look like this. Temperature Selector Bar The bar under your system display lets you select the temperature of the air coming into the passenger area of your vehicle.
Page 125 Left Blend Button (Floor): This setting sends most of the airflow The airflow can be blended between the two positions. through the floor outlets. The rest of the air flows To blend between the positions, press the side of the through the windshield and side window vents.
Page 126: Air Conditioning
OFF: Press this button to turn the air If your air conditioner develops high system pressure, conditioning/heating system off. Pressing OFF will it will automatically go into the MAX mode and REC erase the present mode of operation from the system’s will light on your display.
Page 127: Defogging And Defrosting
Defogging and Defrosting Ventilation System Use DEFOG, along with the floor setting, when there is Air comes into your vehicle in one of two ways: power fog or ice on the windshield. This will direct airflow air or ram air. Power air means bringing outside air into toward the windshield and front side windows.
Page 128: Audio Systems
Ventilation Tips Audio Systems Keep the hood and front air inlet free of ice, snow or Your audio system has been designed to operate easily any other obstruction (such as leaves). The heater and give years of listening pleasure. You will get the and defogger will work far better, reducing the most enjoyment out of it if you acquaint yourself with it chance of fogging the inside of your windows.
Page 129 AM-FM Stereo CALL: Press this button to display the clock for a few seconds when the radio is on. To change what is normally shown on the display (station or time), press this button and the SET button. Finding a Station AM/FM: Press this button to switch between AM and FM.
Page 130 Setting Preset Stations You can also use set the pushbuttons by using the automatic memory. You can set up to 12 stations The six numbered pushbuttons let you return to your (six AM and six FM) by performing the following steps: favorite stations.
Page 131: Remote Cassette Tape Player (If Equipped)
Adjusting the Speakers (Balance/Fade) To load a cassette tape, hold the cassette with the tape to the right. Then, insert the cassette tape. Tape direction is BAL (Balance): Slide this lever to the left or right to displayed by the lighted arrow. To change the tape adjust the speaker balance between the left and right direction, press the FF button.
Page 132: Understanding Radio Reception
Understanding Radio Reception To help avoid hearing loss or damage do the following: 1. Adjust the volume control to the lowest setting. 2. Increase volume slowly until you hear comfortably The range for most AM stations is greater than for and clearly.
Page 133: Care Of Your Cassette Tape Player
Care of Your Cassette Tape Player You may also choose a non scrubbing action, wet type cleaner which uses a cassette with a fabric belt to clean A tape player that is not cleaned regularly can cause the tape head. This type of cleaning cassette will not reduced sound quality, ruined cassettes or a damaged eject on its own.
Page 134: Section 4 Your Driving And The Road
Section 4 Your Driving and the Road Here you’ll find information about driving on different kinds of roads and in varying weather conditions. We’ve also included many other useful tips on driving. Defensive Driving Driving in Rain and on Wet Roads Drunken Driving City Driving Control of a Vehicle...
Page 135: Defensive Driving
Defensive driving really means “be ready for anything.” On city streets, rural roads or freeways, it means “always expect the unexpected.” Assume that pedestrians or other drivers are going to be careless and make mistakes. Anticipate what they might do. Be ready for their mistakes. Rear end collisions are about the most preventable of accidents.
Page 136: Drunken Driving
Drunken Driving Many adults by some estimates, nearly half the adult population choose never to drink alcohol, so they Death and injury associated with drinking and driving is never drive after drinking. For persons under 21, it’s a national tragedy. It’s the number one contributor to against the law in every U.S.
Page 137 According to the American Medical Association, a It’s the amount of alcohol that counts. For example, lb. (82 kg) person who drinks three 12 ounce if the same person drank three double martinis (355 ml) bottles of beer in an hour will end up with a (3 ounces or 90 ml of liquor each) within an hour, BAC of about 0.06 percent.
Page 138 But the ability to drive is affected well below a BAC There’s something else about drinking and driving that of 0.10 percent. Research shows that the driving skills many people don’t know. Medical research shows that of many people are impaired at a BAC approaching alcohol in a person’s system can make crash injuries 0.05 percent, and that the effects are worse at night.
Page 139: Control Of A Vehicle
Control of a Vehicle Braking You have three systems that make your vehicle go where Braking action involves perception time and you want it to go. They are the brakes, the steering and reaction time. the accelerator. All three systems have to do their work First, you have to decide to push on the brake pedal.
Page 140: Hydraulic Brake Systems
Avoid needless heavy braking. Some people drive Hydraulic Brake Systems in spurts heavy acceleration followed by heavy If your engine stops running, or if your primary brake braking rather than keeping pace with traffic. system stops working, your vehicle has a reserve power This is a mistake.
Page 141: Anti-Lock Brake System (Abs)
Anti-Lock Brake System (ABS) Your vehicle has anti lock brakes. ABS is an advanced electronic braking system that will help prevent a braking skid. When you start your engine and begin to drive away, your anti lock brake system will check itself. You may hear a momentary motor or clicking noise while this test is going on.
Page 142: Braking In Emergencies
The anti lock system can change the brake Remember: Anti lock doesn’t change the time you need pressure faster than any driver could. The computer is to get your foot up to the brake pedal or always decrease programmed to make the most of available tire and road stopping distance.
Page 143: Power Steering
Steering The traction you can get in a curve depends on the condition of your tires and the road surface, the Power Steering angle at which the curve is banked, and your speed. While you’re in a curve, speed is the one factor you If you lose power steering assist because the engine can control.
Page 144: Steering In Emergencies
Steering in Emergencies There are times when steering can be more effective than braking. For example, you come over a hill and find a truck stopped in your lane, or a car suddenly pulls out from nowhere, or a child darts out from between parked cars and stops right in front of you.
Page 145: Off-Road Recovery
Road Recovery Passing You may find that your right wheels have dropped off the The driver of a vehicle about to pass another on a edge of a road onto the shoulder while you’re driving. lane highway waits for just the right moment, accelerates, moves around the vehicle ahead, then goes back into the right lane again.
Page 146 Watch for traffic signs, pavement markings and lines. If other cars are lined up to pass a slow vehicle, wait If you can see a sign up ahead that might indicate a your turn. But take care that someone isn’t trying to turn or an intersection, delay your pass.
Page 147: Loss Of Control
Loss of Control A cornering skid and an acceleration skid are usually best handled by easing your foot off the Let’s review what driving experts say about what accelerator pedal. happens when the three control systems (brakes, steering Of course, traction is reduced when water, snow, ice, and acceleration) don’t have enough friction where the gravel or other material is on the road.
Page 148: Driving At Night
Driving at Night Here are some tips on night driving. Drive defensively. Don’t drink and drive. Since you can’t see as well, you may need to slow down and keep more space between you and other vehicles. Slow down, especially on higher speed roads. Your headlamps can light up only so much road ahead.
Page 149 No one can see as well at night as in the daytime. But as Keep your windshield and all the glass on your vehicle we get older these differences increase. A 50 year clean inside and out. Glare at night is made much driver may require at least twice as much light to see the worse by dirt on the glass.
Page 150: Driving In Rain And On Wet Roads
Driving in Rain and on Wet Roads Rain and wet roads can mean driving trouble. On a wet road, you can’t stop, accelerate or turn as well because your tire road traction isn’t as good as on dry roads. And, if your tires don’t have much tread left, you’ll get even less traction.
Page 151 Driving too fast through large water puddles or even going through some vehicle washes can cause problems, too. The water may affect your brakes. Try to avoid puddles. But if you can’t, try to slow down before you hit them. CAUTION: Wet brakes can cause accidents.
Page 152: Driving Through Deep Standing Water
Hydroplaning Driving Through Deep Standing Water Hydroplaning is dangerous. So much water can build up under your tires that they can actually ride on the water. NOTICE: This can happen if the road is wet enough and you’re going fast enough. When your vehicle is hydroplaning, If you drive too quickly through deep puddles it has little or no contact with the road.
Page 153: Driving Through Flowing Water
Driving Through Flowing Water Some Other Rainy Weather Tips Turn on your low beam headlamps and your marker and clearance lamps, if your vehicle has them CAUTION: just your parking lamps to help make you more visible to others. Flowing or rushing water creates strong forces. Besides slowing down, allow some extra following If you try to drive through flowing water, as you distance.
Page 154: City Driving
City Driving Here are ways to increase your safety in city driving: Know the best way to get to where you are going. Get a city map and plan your trip into an unknown part of the city just as you would for a cross country trip.
Page 155: Freeway Driving
Freeway Driving The most important advice on freeway driving is: Keep up with traffic and keep to the right. Drive at the same speed most of the other drivers are driving. Too fast or slow driving breaks a smooth traffic flow. Treat the left lane on a freeway as a passing lane.
Page 156: Highway Hypnosis
Once you are moving on the freeway, make certain you Highway Hypnosis allow a reasonable following distance. Expect to move Is there actually such a condition as “highway hypnosis”? slightly slower at night. Or is it just plain falling asleep at the wheel? Call it When you want to leave the freeway, move to the highway hypnosis, lack of awareness, or whatever.
Page 157: Hill And Mountain Roads
Hill and Mountain Roads and transmission. These parts can work hard on mountain roads. Know how to go down hills. The most important thing to know is this: let your engine do some of the slowing down. Shift to a lower gear when you go down a steep or long hill.
Page 158 Know how to go uphill. Use lower gears. They help cool your engine and transmission, CAUTION: and you can climb the hill better. Stay in your own lane when driving on two lane Coasting downhill in NEUTRAL (N) or with the roads in hills or mountains.
Page 159: Winter Driving
Winter Driving Include an ice scraper, a small brush or broom, a supply of windshield washer fluid, a rag, some winter outer clothing, a small shovel, a flashlight, a red cloth and reflective warning triangles. And, if you will be driving under severe conditions, include a small bag of sand, a piece of old carpet or a couple of burlap bags to help provide traction.
Page 160 Whatever the condition smooth ice, packed, blowing or loose snow drive with caution. Accelerate gently. Try not to break the fragile traction. If you accelerate too fast, the drive wheels will spin and polish the surface under the tires even more. Whatever your braking system, allow greater following distance on any slippery road.
Page 161: If You're Caught In A Blizzard
If You’re Caught in a Blizzard Tie a red cloth to your mirror arm to alert police that you’ve been stopped by the snow. Put on extra clothing or wrap a blanket around you. If you have no blankets or extra clothing, make body insulators from newspapers, burlap bags, rags, floor mats anything you can wrap around yourself or...
Page 162 Run your engine only as long as you must. This saves fuel. When you run the engine, make it go a little faster CAUTION: than just idle. That is, push the accelerator slightly. This uses less fuel for the heat that you get and it Snow can trap exhaust gases under your vehicle.
Page 163: Loading Your Vehicle
Loading Your Vehicle The GVW Rating label is provided by the final manufacturer and should be on the door or door jamb. There is a GVW Rating label on your vehicle that shows It also tells you the maximum weights for the front and how much weight it may properly carry.
Page 164 Using heavier suspension components to get added durability might not change your weight ratings. Ask CAUTION: your dealer to help you load your vehicle the right way. Things you put inside your vehicle can strike NOTICE: and injure people in a sudden stop or turn, or in a crash.
Page 165 Power Take Off (PTO) Controls Engaging PTO (If Equipped) To activate and engage the PTO use the following steps: These controls, located on the end of the multifunction 1. Stop your vehicle. lever and on the instrument panel, regulate the 2.
Page 166 Controlling PTO Operating Speeds The engine speed will return to a normal idle if the brake or clutch pedal is pressed. Your vehicle can be programmed to operate in one of To operate your vehicle in the variable mode, use the two, preset or variable, engine speed operating modes.
Page 167 At this point, the engine speed can be adjusted by doing Move the PTO switch from ON all the way to PTO either of the following: UP (R/A). Hold the switch there until you reach the desired speed; then release the switch. To increase Press in the PTO DOWN (SET) button until you the speed in small amounts, briefly move the switch reach the desired speed;...
Page 168: Section 5 Problems On The Road
Section 5 Problems on the Road Here you’ll find what to do about some problems that can occur on the road. Hazard Warning Flashers Cooling System (Caterpillar Diesel Engine) Other Warning Devices Engine Fan Noise Jump Starting If a Tire Goes Flat Towing Your Vehicle Changing a Flat Tire Engine Overheating...
Page 169: Hazard Warning Flashers
Hazard Warning Flashers The hazard flasher switch is located on the steering column. Press the button in to make your front and rear turn signal lamps flash on and off. Your hazard warning flashers work no matter what Your hazard warning flashers let you warn others. They position your key is in, and even if the key isn’t in.
Page 170 Hazard Warning Flasher Switch (If Equipped) With some options, such as U86 trailer wiring or tractor application, you will have this switch. This switch replaces the hazard switch mounted on the steering column. It is mounted in the instrument panel, usually to the left of and below the steering column.
Page 171: Other Warning Devices
Signal-Stat Turn Signal and Hazard To turn off the flasher, move the turn signal Warning Flasher (If Equipped) lever either up or down. If you have this system, it lets you warn others. It also Then move the signal lever lets police know you have a problem.
Page 172: Jump Starting
Jump Starting NOTICE: If your battery (or batteries) has run down, you may want to use another vehicle and some jumper cables to Ignoring these steps could result in costly start your vehicle. Be sure to follow the steps below to damage to your vehicle that wouldn’t be do it safely.
Page 173 1. Check the other vehicle. It must have a 12 volt To avoid the possibility of vehicles rolling, set the battery with a negative ground system. parking brake firmly on both vehicles involved in the jump start procedure. Put an automatic transmission in PARK (P) or a manual transmission in NEUTRAL NOTICE: before setting the parking brake.
Page 174 CAUTION: CAUTION: Using a match near a battery can cause battery Fans or other moving engine parts can injure you gas to explode. People have been hurt doing this, badly. Keep your hands away from moving parts and some have been blinded. Use a flashlight if once the engine is running.
Page 175 6. Connect the red 8. Now connect the black positive (+) cable negative ( ) cable to the to the positive (+) negative ( ) terminal of terminal of the dead the good battery. Use a battery. Use a remote remote negative ( positive (+) terminal terminal if the vehicle...
Page 176 9. Connect the other end of 11. Try to start the vehicle with the dead battery. the negative ( ) cable at If it won’t start after a few tries, it probably least 18 inches (45 cm) needs service. away from the dead battery, but not near engine parts that NOTICE:...
Page 177 To disconnect the jumper cables from both vehicles, do the following: 1. Disconnect the black negative ( ) cable from the vehicle that had the dead battery. 2. Disconnect the black negative ( ) cable from the vehicle with the good battery. 3.
Page 178: Towing Your Vehicle
Towing Your Vehicle CAUTION: (Continued) Working on air brakes without first using CAUTION: the release studs to compress the springs can lead to injury. Never work on the air To help avoid serious personal injury to you brakes chambers without first using the or others: release studs to compress the brake springs.
Page 179 Before you do anything, turn on the hazard warning Towing Your Vehicle From the Front flashers (if they have not been damaged). (Front Wheels Off the Ground) When you call, tell the towing service: Before Towing That your vehicle has rear wheel drive.
Page 180 Towing the Vehicle with the Front Bumper Removed 4. Connect lift chains to the tow bar and raise the tow bar until lift chain slack has been taken up and the 1. Remove the front bumper. hardwood beam is fully seated against the spring 2.
Page 181 Towing the Vehicle with the Front Bumper Installed 1. Connect and lock the lift chains to the front axle, outside of the spring anchor plates as previously shown. 2. Place a 6 x 6 x 5 hardwood beam underneath and slightly behind the front spring shackle brackets as previously shown.
Page 182 4. Remove the remaining slack in the lift chains. Single Drive Rear Axle The tow bar swing arm should rest against the Disconnect the propshaft at the rear axle. Secure the 2 x 12 x 40 hardwood board as shown. propshaft to the frame or crossmember.
Page 183 Towing Your Vehicle From the Front If there is damage or suspected damage to the axle(s), remove the axle shafts. Cover the hub openings to (All Wheels On the Ground) prevent the loss of lubricant or entry of dirt or Your vehicle may be towed on all wheels provided foreign objects.
Page 184 Releasing Air-Operated Parking Brakes 1. Block the wheels of the vehicle. (If Equipped) If your vehicle has air brakes, you could have a special towing problem. If your vehicle has to be towed because of a complete loss of air pressure from both systems, the parking brakes will have automatically engaged.
Page 185 3. Remove the rubber 6. Using a wrench, turn cap from the rear of the stud nut clockwise the chamber. several turns to release the brakes. Follow the same procedure to release the other brake. 4. Put the release stud, nut and flat washer into 7.
Page 186: Engine Overheating
Engine Overheating CAUTION: You will find a coolant temperature warning gage on your vehicle’s instrument panel, as well as a LOW COOLANT warning light. Your vehicle also has a Steam from an overheated engine can burn you CHECK GAGES warning light on the instrument panel. badly, even if you just open the hood.
Page 187: If No Steam Is Coming From Your Engine
If No Steam Is Coming From Your Engine If you no longer have the overheat warning, you can drive. Just to be safe, drive slower for about An overheat warning, along with a low coolant light, 10 minutes. If the warning doesn’t come back on, can indicate a serious problem.
Page 188: Cooling System (Gasoline Engines)
Cooling System (Gasoline Engines) When you decide it’s safe to lift the hood, here’s what you’ll see: Sloped Hood A. Coolant Recovery Tank B. Engine Fan C. Radiator Pressure Cap If the coolant inside the coolant recovery tank is boiling, don’t do anything else until it cools down.
Page 189 When the engine is cold, the coolant level should be above the HOT LEVEL mark on the vehicle with the specialty hood, or at or above the COLD LEVEL mark on the vehicle with the sloped hood. If it isn’t, you may have a leak at the pressure cap or in the radiator hoses, heater hoses, radiator, water pump or somewhere else in the cooling system.
Page 190: Recovery Tank
How to Add Coolant to the Coolant NOTICE: Recovery Tank If you haven’t found a problem yet, but the coolant Engine damage from running your engine level isn’t at or above the HOT LEVEL mark on the without coolant isn’t covered by your warranty. vehicle with the specialty hood, or at or above the COLD LEVEL mark on the vehicle with the sloped hood, add a 50/50 mixture of clean, drinkable water and...
Page 191 NOTICE: CAUTION: In cold weather, water can freeze and crack the You can be burned if you spill coolant on hot engine, radiator, heater core and other parts. engine parts. Coolant contains ethylene glycol Use the recommended coolant and the proper and it will burn if the engine parts are hot coolant mixture.
Page 192 CAUTION: Steam and scalding liquids from a hot cooling system can blow out and burn you badly. They are under pressure, and if you turn the radiator pressure cap even a little they can come out at high speed. Never turn the cap when the cooling system, including the radiator pressure cap, is hot.
Page 193: How To Add Coolant To The Radiator
How to Add Coolant to the Radiator 2. Then keep turning the pressure cap, 1. You can remove the but now push down radiator pressure as you turn it. cap when the Remove the cooling system, pressure cap. including the radiator pressure cap and upper radiator hose, is...
Page 194 4. Then fill the coolant recovery tank to the HOT 7. By this time, the coolant level inside the radiator LEVEL mark on the vehicle with the specialty hood, filler neck may be lower. If the level is lower, add or approximately one half full on the vehicle with more of the proper DEX...
Page 195: Cooling System
Cooling System If the coolant inside the coolant surge tank is boiling, don’t do anything else until it cools down. (Caterpillar Diesel Engine) When you decide it’s safe to lift the hood, here’s what The coolant level you’ll see: should be at COLD ADD or higher.
Page 196: How To Add Coolant To The Coolant Surge Tank
If there seems to be no leak, start the engine again. The fan speed should increase when idle speed is doubled by CAUTION: pushing the accelerator pedal down. If it doesn’t, your vehicle needs service. Turn off the engine. Heater and radiator hoses, and other engine How to Add Coolant to the Coolant parts, can be very hot.
Page 197 CAUTION: Steam and scalding liquids from a hot cooling system can blow out and burn you badly. They are under pressure, and if you turn the coolant surge tank pressure cap even a little they can come out at high speed. Never turn the cap when the cooling system, including the coolant surge tank pressure cap, is hot.
Page 198 CAUTION: (Continued) With plain water or the wrong mixture, your engine could get too hot but you wouldn’t get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and coolant. NOTICE: In cold weather, water can freeze and crack the engine, radiator, heater core and other parts.
Page 199 2. Then keep turning the cap, but now push down as 3. Then fill the coolant surge tank with the proper you turn it. Remove the pressure cap. coolant mixture, up to the COLD FULL mark. 5-32...
Page 200 4. With the coolant surge tank pressure cap off, start the engine and let it run until you can feel the upper radiator hose getting hot. Watch out for the engine fan. By this time, the coolant level inside the coolant surge tank may be lower.
Page 201: Engine Fan Noise
Engine Fan Noise If a Tire Goes Flat Your vehicle has a clutched engine cooling fan. It’s unusual for a tire to “blow out” while you’re driving, When the clutch is engaged, the fan spins faster to especially if you maintain your tires properly. If air goes provide more air to cool the engine.
Page 202: Changing A Flat Tire
Changing a Flat Tire So if you’re stopped somewhere by a flat or damaged tire or wheel, you should get expert help. See “Roadside Your truck, when new, did not include tire changing Assistance” in the Index. equipment or a place to store a tire in the vehicle. Few drivers of these vehicles have the necessary equipment aboard to be able to change a flat tire safely.
Page 203: If You're Stuck: In Sand, Mud, Ice Or Snow
If You’re Stuck: In Sand, Mud, NOTICE: Ice or Snow In order to free your vehicle when it is stuck, you Spinning your wheels can destroy parts of your will need to spin the wheels, but you don’t want to spin vehicle as well as the tires.
Page 204: Section 6 Service And Appearance Care
Section 6 Service and Appearance Care Here you will find information about the care of your vehicle. This section begins with service and fuel information, and then it shows how to check important fluid and lubricant levels. There is also technical information about your vehicle, and a part devoted to its appearance care.
Page 205: Doing Your Own Service Work
Service Doing Your Own Service Work If you want to do some of your own service work, you’ll Your dealer knows your vehicle best and wants you to want to use the proper service manual. It tells you much be happy with it. We hope you’ll go to your dealer for more about how to service your vehicle than this manual all your service needs.
Page 206: Two Safety Cautions About Engine Fan Breakage
Two Safety Cautions about Engine CAUTION: (Continued) Fan Breakage Winter Fronts, Grille Covers or Obstructions Winter fronts, grille covers or other add CAUTION: equipment causing obstructions in front or behind the fan should not be used on this vehicle. Changing the Fan Drive Ratio or Engine They may increase the stress on the fan as the Governed Speed blades pass over the covered areas.
Page 207: Fuel (Gasoline Engine)
Fuel (Gasoline Engine) Gasoline Specifications It is recommended that gasoline meet specifications If your vehicle has a diesel engine, see “Diesel Engine which were developed by the American Automobile Fuel” in this section. For vehicles with gasoline engines, Manufacturers Association and endorsed by the please read this.
Page 208 Additives You should not have to add anything to your fuel. Gasolines containing oxygenates, such as ethers and Some gasolines that are not reformulated for low ethanol, and reformulated gasolines may be available in emissions may contain an octane enhancing additive your area to contribute to clean air.
Page 209: Diesel Fuel Requirements And Fuel System
Diesel Fuel Requirements and Fuel NOTICE: System Diesel Engine Fuel If there is water in your diesel fuel and the weather is warm or humid, fungus and bacteria See your Caterpillar Diesel Engine Operation & can grow in the fuel. They can damage your Maintenance Manual for information concerning fuel system.
Page 210: Fuels In Foreign Countries
Fuels in Foreign Countries Filling Your Tank (Gasoline Engines) If you plan on driving in another country outside the United States or Canada, the proper fuel may be hard to find. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel.
Page 211 The fuel cap can be on either or both sides of your When you put the cap back on, turn it to the right vehicle depending on option content. (clockwise) until it is tight. To take off the cap, turn it slowly to the left (counterclockwise).
Page 212: Filling A Portable Fuel Container
Filling a Portable Fuel Container Checking Things Under the Hood CAUTION: CAUTION: Never fill a portable fuel container while it is in Things that burn can get on hot engine parts and your vehicle. Static electricity discharge from the start a fire. These include liquids like fuel, oil, container can ignite the gasoline vapor.
Page 213: Hood Latches
Hood Latches Then take the hand holds and pull the hood forward. To tilt the hood forward, pull out on each of the hood latches. If the hood is equipped with hood access panels, make sure the panel latches are locked down before lifting the hood open.
Page 214 When you tilt the hood far enough, the cables will If your vehicle has the optional hood access panels, support it. you can easily get to one side of the engine or the other as you need to. Pull out on the top of each hood latch. Then push the latch down and swing the bottom out.
Page 215: Noise Control System
Place the prop rod, located Noise Control System on the panel, where the The following information relates to compliance with arrow is pointing. federal noise emission standards for vehicles with a Gross Vehicle Weight Rating (GVWR) of more than 10,000 lbs. (4 536 kg). The Maintenance Schedule provides information on maintaining the noise control system to minimize degradation of the noise emission control system during the life of your vehicle.
Page 216: Tampering With Noise Control System Prohibited
Tampering With Noise Control Insulation: System Prohibited Removal of the noise shields or any underhood insulation. Federal law prohibits the following acts or the causing thereof: Engine: 1. The removal or rendering inoperative by any person, Removal or rendering engine speed governor other than for purposes of maintenance, repair or (if equipped) inoperative so as to allow engine replacement, of any device or element of design...
Page 217: Engine Oil (Gasoline Engine)
Engine Oil (Gasoline Engine) Turn off the engine and give the oil several minutes to drain back into the oil pan. If you don’t, the oil dipstick Checking Engine Oil might not show the actual level. Pull out the dipstick and clean it with a paper towel or It’s a good idea to check your engine oil every time you cloth, then push it back in all the way.
Page 218: When To Add Engine Oil
NOTICE: Don’t add too much oil. If your engine has so much oil that the oil level gets above the cross hatched area that shows the proper operating range, your engine could be damaged. Be sure to fill it enough to put the level somewhere in the proper operating range.
Page 219: What Kind Of Engine Oil To Use
What Kind of Engine Oil to Use Oils recommended for your vehicle can be identified by looking for the starburst symbol. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). Do not use any oil which does not carry this starburst symbol.
Page 220: Engine Oil Additives
As in the chart shown previously, SAE 5W 30 is best for Engine Oil Additives your vehicle. However, you can use SAE 10W 30 if it’s Don’t add anything to your oil. The recommended oils going to be 0 C) or above. These numbers on with the starburst symbol are all you will need for good an oil container show its viscosity, or thickness.
Page 221: What To Do With Used Oil
If the system is ever reset accidentally, you must change What to Do with Used Oil your oil at 3,000 miles (5 000 km) since your last oil Used engine oil contains certain elements that may be change. Remember to reset the oil life system whenever unhealthy for your skin and could even cause cancer.
Page 222: Engine Air Cleaner/Filter
Engine Oil (Caterpillar Your gasoline or diesel engine has a restriction indicator that lets you know when the engine air cleaner/filter is Diesel Engines) dirty and needs to be serviced. It is located in the air intake tube below the air cleaner on the passenger’s side See your Caterpillar Operation &...
Page 223 When the yellow indicator reaches the CAUTION: red ring in the sight glass of this indicator, Gasoline Engines Only: Operating the engine it’s time to service the with the air cleaner/filter off can cause you or engine air cleaner/filter. others to be burned. The air cleaner not only cleans the air, it stops flame if the engine backfires.
Page 224: Automatic Transmission Fluid
Automatic Transmission Fluid Automatic Transmission External Filter With Service Trans Filter Indicator When to Check Light (Option) A good time to have it checked is when the engine oil If your vehicle has this option, the filter location is is checked. See your Allison Automatic Transmission different with different transmissions.
Page 225: Manual Transmission Fluid
Manual Transmission Fluid How to Add Fluid Here’s how to add fluid. Refer to the Maintenance When to Check Schedule to determine the proper fluid to use. See A good time to have it checked is when the engine oil is “Recommended Fluids and Lubricants”...
Page 226: How To Check Lubricant
Rear Axle If the level is below the bottom of the filler plug hole, you’ll need to add some lubricant. Add enough lubricant When to Check and Change Lubricant to raise the level to the bottom of the filler plug hole. Refer to the Maintenance Schedule to determine how What to Use often to check the lubricant and when to change it.
Page 227 Engine Coolant (Gasoline Engine) NOTICE: The cooling system in your vehicle is filled with COOL engine coolant. This coolant is designed When adding coolant, it is important that you to remain in your vehicle for 5 years or 150,000 miles COOL R (silicate use only DEX free) coolant.
Page 228: What To Use
What to Use NOTICE: Use a mixture of one half clean, drinkable water and half DEX COOL coolant which won’t damage If you use an improper coolant mixture, your aluminum parts. If you use this coolant mixture, you engine could overheat and be badly damaged. don’t need to add anything else.
Page 229: Checking Coolant
Checking Coolant Coolant Recovery Tank (Gasoline Engines Sloped Hood) Coolant Recovery Tank (Gasoline Engines Specialty Hood) 6-26...
Page 230 When your engine is cold, the coolant level should be at the COLD level, or a little higher, on the coolant recovery tank with the gasoline engine, or at the COLD FULL mark, visible through the surge tank, with the diesel engine.
Page 231: Engine Coolant
Adding Coolant CAUTION: If you need more coolant, add the proper DEX COOL coolant mixture at the coolant recovery tank or the surge tank. You can be burned if you spill coolant on hot engine parts. Coolant contains ethylene glycol, and it will burn if the engine parts are hot CAUTION: enough.
Page 232: Radiator Pressure Cap
Radiator Pressure Cap Surge Tank Pressure Cap (Gasoline Engines) (Diesel Engines) The radiator pressure cap The surge tank pressure cap must be tightly installed must be tightly installed with the arrows on the cap with the arrows on the cap lined up with the top of the lined up with the top tube overflow tube.
Page 233: How To Check Power Steering Fluid
Power Steering Fluid What to Use To determine what kind of fluid to use, see See your Maintenance Schedule for when to check your “Recommended Fluids and Lubricants” in the Index. power steering fluid. How To Check Power Steering Fluid NOTICE: Check your power steering fluid only when the engine is warm.
Page 234: Windshield Washer Fluid
Windshield Washer Fluid NOTICE: What to Use When using concentrated washer fluid, When you need windshield washer fluid, be sure to read follow the manufacturer’s instructions for the manufacturer’s instructions before use. If you will be operating your vehicle in an area where the temperature adding water.
Page 235: Brake Fluid
Brakes Checking Brake Fluid Apply the brake pedal several times with the ignition Brake Fluid off. Then clean one of the reservoir caps and the area If your vehicle has around the cap, and remove it. The fluid level should be hydraulic brakes, even with the bottom ring of the filler opening.
Page 236 What to Add NOTICE: Use the proper fluid listed in your Maintenance Schedule. Use new brake fluid from a sealed Using the wrong fluid can badly damage container only. brake system parts. For example, just a few Always clean the brake fluid reservoir cap and the area drops of mineral based oil, such as engine around the cap before removing it.
Page 237: Brake Adjustment
Four-Wheel Disc Brakes (Hydraulic Only) Brake Pedal Travel Your vehicle has four wheel disc brakes. See your dealer if the brake pedal does not return to normal height, or if there is a rapid increase in pedal Some driving conditions or climates may cause a brake travel.
Page 238 Air Brake Systems (If Equipped) Moisture Ejector(Option) If you have air brakes, it is important to get rid of If you have air brakes with a moisture ejector, the valve moisture in the system. Moisture will damage your automatically ejects moisture from the reserve tank system if it isn’t removed daily.
Page 239: How To Check And Add Fluid
Electric/Hydraulic Parking How to Check and Add Fluid Brake Fluid Be sure the parking brake is firmly set. To check the fluid level, look at the MAX and MIN lines on the If you have an electric/hydraulic parking brake, a good side of the reservoir.
Page 240: Clutch Pedal Free Travel
Clutch Pedal Free Travel Chassis Lubrication If you have a manual transmission, your clutch will Your Maintenance Schedule provides all of the required need adjustment when pedal free travel gets down to chassis lubrication intervals and identifies proper about 1 1/4 inch (32 mm), as measured at the clutch lubricants to use.
Page 241 Single Axle Models 6-38...
Page 242 ITEM NO. ITEM REMARKS Brake Camshaft , Brake One fitting each (apply sparingly). For caliper rails, Caliper Rails (If Equipped)$ apply Aero Shell #5 Lubricant. Steering Column Slip Joint* One fitting. Steering Drag Link Ends One fitting at each end. One fitting each joint.
Page 243 ITEM NO. ITEM REMARKS Parking Brake Bell Crank*$ One fitting. Transmission Fill to level of filler plug. Check fluid level. Transmission Auto* Propshaft Slip Joint One fitting each joint; lubricate with GM Part No. 1051344 Wheel Bearing Lubricant. One fitting each joint (1480 and 1550 Series); lubricate Propshaft U Joints with GM Part No.
Page 244 Tandem Axle Models ITEM REMARKS ITEM Brake Camshafts One fitting each. Propshaft One fitting each joint (1480 and 1550 Series). Joint Lubricate with GM Part No. 1051344, Wheel Bearing Lubricant. Brake Shoe Apply engine oil at pin to shoe joint only. Roller Pins Rear Spring Pin One fitting each side.
Page 245: Vehicle Storage
Battery CAUTION: Your new vehicle comes with one or more maintenance free ACDelco batteries. When it’s time for a new battery, be sure it has the replacement number shown Batteries have acid that can burn you and gas on the original battery’s label. We recommend an that can explode.
Page 246: Windshield Wiper Blade Replacement
Windshield Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a year for wear or cracking. See “Wiper Blade Check” in the Index for more information. Replacement blades come in different types and are removed in different ways. Here’s how to remove the Shephard’s Hook type: 1.
Page 247: Other Service Items
Other Service Items Component Box Your vehicle has a component box located along the driver’s side frame rail. What is in the box depends on what options are on your vehicle. Normally, the fuel filter, air dryer, Luberfiner oil filter, emission canister or other components are in there.
Page 248 Fuel Filter (Gasoline Engines) Primary Fuel Filter and Water Separator (Option) The steel fuel filter is located on the inside of the left hand frame rail. See “Maintenance Schedule” in the If you have a Caterpillar Index for recommended service intervals. diesel engine, you may have this spin on filter.
Page 249 Secondary Fuel Filter and Water Automatic Ether Injection System (Option) Separator/Heater (Option) If your diesel engine vehicle has this feature, the ether If you have a Caterpillar cylinder is located on the diesel engine, you may upper right rear side of the have this spin on filter engine compartment.
Page 250: Front Wheel Bearings With Oil-Filled Hubs
6. Install a new gasket whenever you take out the If there isn’t, clean the rubber fill plug in the center of cylinder. Use only one gasket and spread a light film the glass, and then remove it. Be careful not to allow of clean oil on it before installation.
Page 251 Tires CAUTION: (Continued) Your new vehicle comes with high quality tires made by a leading tire manufacturer. If you ever have questions Underinflated tires pose the same danger about your tire warranty and where to obtain service, see as overloaded tires. The resulting accident your GM Warranty booklet for details.
Page 252: Inflation -- Tire Pressure
Inflation -- Tire Pressure NOTICE: (Continued) The GVW Rating label, which is on the driver’s door, shows the correct inflation pressures for your If your tires have too much air (overinflation), tires when they’re cold. “Cold” means your vehicle has you can get the following: been sitting for at least three hours or driven no more Unusual wear...
Page 253: Rims And Wheels
Rims and Wheels If you’re going to be doing a lot of driving on high crown roads, you can reduce tire wear by adding Rims and wheels are stamped with a maximum load 5 psi (35 kPa) to the tire pressure in the outer tires. and cold inflation rating.
Page 254: When It's Time For New Tires
When It’s Time for New Tires When you replace tires, make sure they are the same size, load range, speed rating and construction type Replace your tires when the tread depth is down to 1/8 of (bias, bias belted or radial) as your original tires. an inch (3.2 mm) for the front tires, or 1/16 of an inch (1.6 mm) for a rear tire.
Page 255: Tightening The Wheel Nuts
Tightening the Wheel Nuts First, use these pictures to decide what kind of wheels you have. CAUTION: Wheel nuts that are not tight can work loose. If all the nuts on a wheel come off, the wheel can come off the vehicle, causing a crash. All wheel nuts must be properly tightened.
Page 256 Then, follow the steps below for the wheels you have. 2. Put the tire and rim assembly on the axle hub. Install the outer rear tire and rim assembly so that its valve stem is exactly opposite the valve stem on CAUTION: the inner tire and rim assembly.
Page 257 6. Tighten the nuts to 400 lb ft (542 N·m) if an eight hole stud or 480 lb ft (650 N·m) if a 10 hole stud. Follow CAUTION: the diagrams below. If wheel studs are damaged, they can break. If all the studs on a wheel broke, the wheel could come off and cause a crash.
Page 258: Wheel Replacement
Wheel Replacement CAUTION: Replace any wheel that is bent, cracked or badly rusted. If wheel nuts keep coming loose, replace the wheel. If the wheel leaks air, replace it. Rust or dirt on a wheel, or on the parts to which it is fastened, can make the wheel nuts become Your dealer will know the kind of wheel you need.
Page 259 NOTICE: CAUTION: The wrong wheel can cause trouble in bearing Without the correct wheel, you may not be life, brake cooling, speedometer/odometer able to stop properly, and you could have other calibration, headlamp aim, bumper height, problems like a tire air out.
Page 260: Appearance Care
Appearance Care Don’t use any of these unless this manual says you can. In many uses, these will damage your vehicle: Remember, cleaning products can be hazardous. Some Alcohol are toxic. Others can burst into flame if you strike a match or get them on a hot part of the vehicle.
Page 261: Using Cleaner On Fabric
Here are some cleaning tips: Special Fabric Cleaning Problems Always read the instructions on the cleaner label. Stains caused by such things as catsup, coffee (black), egg, fruit, fruit juice, milk, soft drinks, vomit, urine and Clean up stains as soon as you can before they set.
Page 262: Care Of Safety Belts
Cleaning Vinyl Care of Safety Belts Use warm water and a clean cloth. Keep belts clean and dry. Rub with a clean, damp cloth to remove dirt. You may have to do it more than once. CAUTION: Things like tar, asphalt and shoe polish will stain if you don’t get them off quickly.
Page 263: Cleaning Glass Surfaces
Cleaning Glass Surfaces Cleaning the Outside of the Windshield and Wiper Blades Glass should be cleaned often. GM Glass Cleaner or a liquid household glass cleaner will remove normal If the windshield is not clear after using the windshield tobacco smoke and dust films on interior glass. washer, or if the wiper blade chatters when running, See “Appearance Care and Materials”...
Page 264: Cleaning The Outside Of Your Vehicle
Weatherstrips Don’t use cleaning agents that are petroleum based, or that contain acid or abrasives. All cleaning agents Silicone grease on weatherstrips will make them should be flushed promptly and not allowed to dry on last longer, seal better, and not stick or squeak. the surface, or they could stain.
Page 265: Protecting Exterior Bright Metal Parts
Your vehicle may have a “basecoat/clearcoat” paint Exterior painted surfaces are subject to aging, weather finish. The clearcoat gives more depth and gloss to the and chemical fallout that can take their toll over a period colored basecoat. Always use waxes and polishes that of years.
Page 266: Cleaning Tires
Cleaning Aluminum or Cleaning Tires Chrome Plated Wheels (If Equipped) To clean your tires, use a stiff brush with a tire cleaner. Keep your wheels clean using a soft clean cloth with mild soap and water. Rinse with clean water. NOTICE: After rinsing thoroughly, dry with a soft clean towel.
Page 267: Finish Damage
Finish Damage Underbody Maintenance Any stone chips, fractures or deep scratches in the finish Chemicals used for ice and snow removal and dust should be repaired right away. Bare metal will corrode control can collect on the underbody. If these are quickly and may develop into a major repair expense.
Page 268: Gm Vehicle Care/Appearance Materials
GM Vehicle Care/Appearance Materials 6-65...
Page 269: Vehicle Identification Number (Vin)
Vehicle Identification Number (VIN) Service Statement One of these statements is on your GVW Rating label. Here is what each one means. TRUCK SERVICE A vehicle made to carry property or special equipment. It is made for uniform frame loading. That includes using the vehicle to pull a full trailer.
Page 270: Service Parts Identification Label
Service Parts Identification Label Headlamp Wiring The headlamp wiring is protected by a circuit breaker You’ll find this label in a location determined by the in the light switch. An electrical overload will cause the body manufacturer. It’s very helpful if you ever need to lights to go on and off, or in some cases to remain off.
Page 271: Power Windows And Other Power Options
The hydraulic brake booster motor feed circuit and Instrument Panel Circuit Breaker Block starter relay circuit are protected by a fusible link. This fuse block is in Vehicles with a diesel engine have a fusible link for the the lower portion of the intake heater feed circuit.
Page 272 These circuit breakers are non cycling; do not replace Name Circuits Protected them with cycling circuit breakers. Also, don’t use HYD BRK Brake Pump Motor Relay, Alarm circuit breakers of higher amperage than those indicated Module on the circuit breaker block. ENG1 Engine Control Module (Diesel Engines), Canister Purge,...
Page 273 Name Circuits Protected Name Circuits Protected A/C Clutch Compressor, A/C AXLE Heated Mirrors, Radiator Shutters, Controller, A/C Clutch Relay Speed Axle Motor, Speed Axle Switch TRN/HAZ Turn Signal Lamps, Hazard Lamps MKR LP Roof Marker Lamps, Trailer Marker Lamps, Marker Lamp CHAS Air Suspension Dump Valve, Relay...
Page 274 Name Circuits Protected IGN SW Instrument Panel Cluster Telltales, Daytime Running Lamp Module, Daytime Running Lamp Relay, Alarm Module, Ignition 1 Relay, Vehicle Interface Module (Diesel Engines), Parking Brake Module, Transmission Relay Coil Auxiliary Wiring (Ignition) Radio, Auxiliary Wiring ENG3 Ignition Coils (Odd), Fuel Injectors Odd Bank (Gasoline Engines), Transmission Control...
Page 275 Vehicles with Hydraulic Brakes Vehicles with Air Brakes 6-72...
Page 276: Replacement Bulbs
Circuits/Circuit Circuits/Circuit Name Breakers Protected Name Breakers Protected STP/HAZ Stoplamp, Turn Signal/Hazard Window, Door Locks TURN Lights, Fuel WDO/LCKS IGN SW3 Air Conditioner, Ignition Switch, PARK BRK Parking Brake Motor Axle, Chassis, Ignition Relay TRLR Trailer INT/EXT Parking Lamps, Dome/Panel BLOWER Blower, Horn, Cigarette LIGHTS...
Page 277: Capacities And Specifications
Capacities and Specifications Crankcase Capacity Capacities (volumes) shown are for normal refill. Add Engine Identification and Data oil as indicated when the oil filter element is changed. Engine RPO Capacities given are approximate keep level within the operating range. Do not operate with fluid level Engine Type 7.2L L6 8.1L V8...
Page 278: Fuel Tank Capacity
Fuel Tank Capacity Manual Transmission Pints (Liters) FS4205A, FS4205B, FS4205C ..11.1 (5.3) Model U.S. Gallons (Liters) FS5205A, FS5205C ....11.6 (5.5) Standard .
Page 279 Rear Axle Lubricant Capacity Tandem Axles Lubricant, Pints (Liters) DS344 (front) ..... 31.0 (14.5) Single Speed Axle Lubricant, Pints (Liters) RS344 (rear) .
Page 280: Normal Maintenance Replacement Parts
Normal Maintenance Allison Transmission External Filters Replacement Parts Engine AC Part Number 7.2L ....... . PF897 Replacement part numbers listed in this section are 8.1L...
Page 281 Service Replacement Part and Filter Recommendations Engine 7.2L 8.1L Spark Plug Denso Type TJ14R 0.060 inch (1.52 mm) Torque 14.75 lb. ft. (20.0 Nm) Oil Filter 1R0739 ACDelco Air Cleaner Donaldson P522606 ACDelco A1518C Fuel Filter ACDelco 915 Primary** ACDelco GF626* Secondary Fuel Filter 1R0751...
Page 282: Section 7 Maintenance Schedule
Section 7 Maintenance Schedule This section covers the maintenance required for your vehicle. Your vehicle needs these services to retain its safety, dependability and emission control performance. Introduction Part B: Owner Checks and Services Part A: Scheduled Maintenance Services Part C: Recommended Fluids and Lubricants Scheduled Maintenance Part D: Maintenance Record...
Page 283: Your Vehicle And The Environment
Introduction Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your vehicle in good working condition, but also helps the environment. All recommended maintenance procedures are important. Improper vehicle maintenance can even affect the quality of the air we breathe. Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle.
Page 284: How This Section Is Organized
How This Section is Organized “Part B: Owner Checks and Services” tells you what should be checked and when. It also explains This maintenance schedule is divided into four parts: what you can easily do to help keep your vehicle in good condition.
Page 285: Using Your Maintenance Schedule
Part A: Scheduled The proper fluids and lubricants to use are listed in Part C. Make sure whoever services your vehicle uses Maintenance Services these. All parts should be replaced and all necessary repairs done before you or anyone else drives Using Your Maintenance Schedule the vehicle.
Page 286: Scheduled Maintenance
Scheduled Maintenance 100 Miles (160 km) Wheel stud nut service. (46) The services shown in this schedule up to 100,000 miles (166 000 km) should be repeated after 100,000 miles 1,000 Miles (1 600 km) (166 000 km) at the same intervals for the life of Wheel stud nut service.
Page 287 6,000 Miles (10 000 km) (Continued) Wheels and tires service. (15)(46) Hydraulic brake service (or every 6 months, Lubricate door hinge pins and rollers with engine oil. whichever occurs first). (7) Wheels and tires service. (15)(46) Hydraulic parking brake service (or every 6 months, Hydraulic brake service (or every 6 months, whichever occurs first).
Page 288 Spring axle U bolts and shackle Clutch pedal free travel service. (10) bolts service. (16) Clean air brake application valve (or every 3 months, Exhaust system service (or every 6 months, or every 300 hours, whichever occurs first); whichever occurs first). (3)(4)(17) lubricate linkage.
Page 289 24,000 Miles (40 000 km) (Continued) 27,000 Miles (45 000 km) Wheels and tires service. (15)(46) Check Oil Life Monitor. If engine oil and filter are changed, reset monitor. See “Engine Oil” in Hydraulic brake service (or every 6 months, the Index.
Page 290 Air brake service (or every 6 months, whichever Chassis lubrication service (or every 6 months, occurs first). (39) whichever occurs first). (12) Lubricate door hinge pins and rollers with engine oil. Inspect door hinge pins and bushings and replace as necessary. Lubricate door hinge pins and rollers Wheels and tires service.
Page 291 39,000 Miles (65 000 km) 45,000 Miles (75 000 km) Check Oil Life Monitor. If engine oil and filter Check Oil Life Monitor. If engine oil and filter are changed, reset monitor. See “Engine Oil” in are changed, reset monitor. See “Engine Oil” in the Index.
Page 292 Lubricate door hinge pins and rollers with engine oil. Air brake chamber service (or every 2 months, whichever occurs first). (41) Wheel bearing (grease type) service (or every 24 months, whichever occurs first, and whenever Trailer brake hand control valve service (or every hubs are removed).
Page 293 54,000 Miles (90 000 km) (Continued) 60,000 Miles (100 000 km) Hydraulic brake service (or every 6 months, Check Oil Life Monitor. If engine oil and filter whichever occurs first). (7) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Hydraulic brake caliper service (or every 6 months, whichever occurs first).
Page 294 Wheels and tires service. (15)(46) 66,000 Miles (110 000 km) Hydraulic brake service (or every 6 months, Check Oil Life Monitor. If engine oil and filter whichever occurs first). (7) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Hydraulic parking brake service (or every 6 months, whichever occurs first).
Page 295 72,000 Miles (120 000 km) Clutch pedal free travel service. (10) Thermostatically controlled engine cooling Check Oil Life Monitor. If engine oil and filter fan service. (4)(20) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Shields and underhood insulation service. (4)(5)(21) Check fluid levels (or every 3 months, whichever Air intake system service (or every 24 months, occurs first).
Page 296 75,000 Miles (125 000 km) Wheels and tires service. (15)(46) Hydraulic brake service (or every 6 months, Check Oil Life Monitor. If engine oil and filter whichever occurs first). (7) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Hydraulic parking brake service (or every 6 months, whichever occurs first).
Page 297 84,000 Miles (140 000 km) (Continued) 90,000 Miles (150 000 km) Lubricate door hinge pins and rollers with engine oil. Check Oil Life Monitor. If engine oil and filter are changed, reset monitor. See “Engine Oil” in Wheels and tires service. (15)(46) the Index.
Page 298 Wheels and tires service. (15)(46) 96,000 Miles (160 000 km) Hydraulic brake service (or every 6 months, Check Oil Life Monitor. If engine oil and filter whichever occurs first). (7) are changed, reset monitor. See “Engine Oil” in the Index. (3)(9) Hydraulic brake caliper service (or every 6 months, whichever occurs first).
Page 299 96,000 Miles (160 000 km) (Continued) 100,000 Miles (166 000 km) Shields and underhood insulation service. (4)(5)(21) Change power steering fluid (or every 24 months, whichever occurs first). (13) Air intake system service (or every 24 months, whichever occurs first). (4)(5)(24) Replace power steering reservoir filter element (or every 24 months, whichever occurs first).
Page 300 250,000 Miles (400 000 km) Footnotes Wheel bearings service Eaton Axle (oil filled) = The U.S. Environmental Protection Agency or the (or every 36 months, whichever occurs first). (23)(48) California Air Resources Board has determined that the Rear axle service Eaton, Rockwell, Spicer Axles failure to perform this maintenance item will not nullify (or every 36 months, whichever occurs first).
Page 301 (7) = Inspect brake lines and hoses for proper hook (10) = Check clutch pedal for free travel. Press pedal binding, leaks, cracks, chafing, etc. Inspect disc brake by hand until resistance is felt. Free travel should be pads for wear and rotors for surface condition. Check maintained at 1.5 to 2 inches (38 to 51 mm) measured brake pedal for excessive free play or travel (or every at the clutch pedal pad.
Page 302 (13) = Check steering system: (16) = Check spring axle U bolts and shackle bolts for proper torque. See the service manual for torque Look for damaged, loose or missing parts. Also look sequence and specifications. When parts are replaced, for parts showing signs of wear or lack of the torque must be checked and adjusted more often lubrication.
Page 303 (23) = Wheel bearing service: (26) = Evaporative Control System Service (if equipped): Check all fuel and vapor lines and hoses Grease type Clean, inspect and lubricate with the for proper connections and any damage (or every proper wheel bearing grease at designated intervals 24 months, whichever occurs first).
Page 304 (35) = Drain, flush and refill cooling system. See Test air lines for leaks; tighten as needed. Replace “Recommended Fluids and Lubricants” in the Index compressor filter. for what to use. Inspect hoses. Clean radiator, condenser, Inspect air parking brake chamber for leaks and pressure cap and neck.
Page 305 (44) = Air brake service: Remove, disassemble, clean (47) = Service is required now if you operate under any and inspect the safety valve, standard brake chamber, of these Short Trip/City conditions: quick release valve, quick release/double check valve Most trips are less than 5 to 10 miles (8 to 16 km). combination, parking brake control valve, double check This is particularly important when outside valve, pressure protection valve and alcohol injector.
Page 306: At Each Fuel Fill
Part B: Owner Checks and Services Engine Coolant Level Check Check the engine coolant level and add DEX COOL Listed in this part are owner checks and services which coolant mixture if necessary. See “Engine Coolant” in should be performed at the intervals specified to help the Index for further details.
Page 307 Wiper Blade Check Parking Brake Check Inspect wiper blades for wear or cracking. Replace blade Park on a fairly steep hill and hold the vehicle with the inserts that appear worn or damaged or that streak or parking brake only. This checks holding ability. miss areas of the windshield.
Page 308 Automatic Transmission Shift Indicator Check Engine Cooling System Service Check that the indicator points to the gear chosen. Inspect the hoses and have them replaced if they are cracked, swollen or deteriorated. Inspect all pipes, Steering Check fittings and clamps; replace as needed. Clean the outside of the radiator and air conditioning condenser.
Page 309 Defroster Check Glass, Mirrors, Lamps and/or Reflectors Condition Check Move the control to the defrost symbol and the fan to HI or the high symbol. Then check the airflow from the Look for broken, scratched, dirty or damaged glass, ducts at the inside base of the windshield. mirrors, lamps or reflectors that could reduce the view or visibility or cause injury.
Page 310 Fluid Leaks Check At Least Once a Year Check for fuel, coolant, oil or other fluid leaks by Key Lock Cylinders Service looking at the surface beneath the vehicle after it has been parked for awhile. Lubricate the key lock cylinders with the lubricant specified in Part C.
Page 311 Part C: Recommended Fluids USAGE FLUID/LUBRICANT and Lubricants Engine Coolant 50/50 mixture of clean, (Gasoline drinkable water and use only Fluids and lubricants identified below by name, Engine & GM Goodwrench COOL part number or specification may be obtained from DURAMAX or Havoline COOL...
Page 312 USAGE FLUID/LUBRICANT USAGE FLUID/LUBRICANT Clutch Bearing Clutch Bearing Lubricant Power GM Power Steering Fluid Lubricant (GM Part No. 12378484 or Steering System (GM Part No. 1052884 1 pint, equivalent NLGI #3 consistency). 1050017 1 quart, or equivalent). Exhaust Brake High Temperature Grease Manual Synthetic Manual Transmission...
Page 313 USAGE FLUID/LUBRICANT USAGE FLUID/LUBRICANT Front Wheel Wheel bearing lubricant meeting Propshafts Wheel bearing lubricant meeting Bearing Grease requirements of NLGI # 2, and Splines requirements of NLGI # 2, (Except Oil Category GC or GC LB (GM Part Category GC or GC LB (GM Part Filled Hubs) No.
Page 314: Maintenance Record
Part D: Maintenance Record After the scheduled services are performed, enter the date, odometer reading and services performed on the maintenance record charts provided here. Any additional information from “Owner Checks and Services” can be added on the following record pages. Also, you should retain all maintenance receipts. Your owner information portfolio is a convenient place to store them.
Page 315 Maintenance Record ODOMETER DATE SERVICED BY MAINTENANCE PERFORMED READING 7-34...
Page 316 Maintenance Record ODOMETER DATE SERVICED BY MAINTENANCE PERFORMED READING 7-35...
Page 317 Maintenance Record ODOMETER DATE SERVICED BY MAINTENANCE PERFORMED READING 7-36...
Page 318: Section 8 Customer Assistance Information
Section 8 Customer Assistance Information Here you will find out how to contact GMC if you need assistance. This section also tells you how to obtain service publications and how to report any safety defects. Customer Satisfaction Procedure Reporting Safety Defects to the United...
Page 319: Customer Satisfaction Procedure
Customer Your satisfaction and goodwill are important to your Assistance Representative: dealer and to GMC. Normally, any concerns with the Vehicle Identification Number (This is available sales transaction or the operation of your vehicle will be from the vehicle registration or title, or the plate resolved by your dealer’s sales or service departments.
Page 320: Customer Assistance For Text Telephone (Tty) Users
General Motors of Canada Limited GMC encourages customers to call the toll-free number Customer Communication Centre, 163-005 for assistance. If a U.S. customer wishes to write to GMC, 1908 Colonel Sam Drive the letter should be addressed to GMC’s Medium Duty Oshawa, Ontario L1H 8P7 Truck Customer Assistance Center.
Page 321: All Overseas Locations
All Overseas Locations Roadside Assistance Please contact the local General Motors Business Unit. Mexico, Central America and Caribbean Islands/Countries (Except Puerto Rico and U.S. Virgin Islands) General Motors de Mexico, S. de R.L. de C.V. Customer Assistance Center Paseo de la Reforma # 2740 Col.
Page 322: Warranty Information
Should you have any questions about campaign. However, NHTSA cannot become involved Roadside Assistance, call the GMC Roadside Assistance in individual problems between you, your dealer or Center or contact your dealer.
Page 323: Reporting Safety Defects To The Canadian Government
Please call us at 1 CHEVY (1 4389), Motors of Canada Limited. You may write to: or write: Transport Canada GMC Truck 330 Sparks Street Customer Assistance Center Tower C P.O. Box 44947 Ottawa, Ontario K1A 0N5 Detroit, MI 48244...
Page 324: Service Publications Ordering Information
SERVICE PUBLICATIONS ORDERING INFORMATION Service Manuals Owner’s Information Service Manuals have the diagnosis and repair Owner publications are written specifically for owners information on engines, transmission, axle, suspension, and intended to provide basic operational information brakes, electrical, steering, body, etc. about the vehicle.

GMC C series 2002 Owner's Manual

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