Page 1 This section tells you when to perform vehicle maintenance and what fluids and lubricants to use. Customer Assistance Information This section tells you how to contact GMC for assistance and how to get service and owner publications. It also gives you information on “Reporting Safety Defects” on page 8 Index Here’s an alphabetical listing of almost every subject in this manual.
Page 2: For Canadian Owners Who Prefer A French Language Manual
We support voluntary technician certification. GENERAL MOTORS, GM, the GM Emblem, GMC and the GMC 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 in the product after that time without further notice.
Page 3: How To Use This Manual
yellowblue 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 4: Vehicle Damage Warnings
yellowblue Vehicle Damage Warnings In the notice area, we tell you about something that can damage your vehicle. Many times, this damage would Also, in this book you will find these notices: not be covered by your warranty, and it could be costly. But the notice will tell you what to do to help avoid the damage.
Page 5: Vehicle Symbols
yellowblue Vehicle Symbols These are some of the symbols you may find on your vehicle. For example, These symbols These symbols These symbols These symbols Here are some these symbols are important have to do with are on some of are used on other symbols are used on an...
Page 6: Model Reference
yellowblue Model Reference Since T-Series models delivered from the factory are finished in a variety of ways by a number of companies, This manual contains information which covers tilt you’ll probably find other manuals in your finished cab models as shown. Most models are unfinished vehicle.
Page 7: Section 1 Seats And Restraint Systems
yellowblue 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 (If Equipped) Safety Belts: They’re for Everyone Children...
Page 8: Seats And Seat Controls
yellowblue Seats and Seat Controls To tilt the seatback, turn the backrest tilt knob. The knob This section tells you about the seats in your vehicle and is located on the lower how to adjust them properly. cushion, on the outboard side of the driver’s seat and Bucket Seats the inboard side of the...
Page 9: Head Restraints
yellowblue To fold the seatback down, push the lever located on CAUTION: the right hand side of the seat toward the rear of You can lose control of the vehicle if you try to the vehicle. 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: Safety Belts: They're For Everyone
yellowblue 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 11: Why Safety Belts Work
yellowblue In most states and Canadian provinces, the law says to Why Safety Belts Work wear safety belts. Here’s why: They work. Aren’t safety belts for kids? You never know if you’ll be in a crash. If you do have a crash, you don’t know if it will be a bad one.
Page 12 yellowblue If the vehicle hits something, it stops right then. But Then something will stop them. It could be nothing stops the people. They keep moving. the windshield.
Page 13 yellowblue 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 14 yellowblue 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 15: How To Wear Safety Belts Properly
yellowblue How to Wear Safety Belts Properly Adults This part is only for people of adult size. Be aware that there are special things to know about safety belts and children. And there are different rules for smaller children and babies. If a child will be riding in your vehicle, see the part of this manual called “Children.”...
Page 16 yellowblue 4. Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. 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.
Page 17 yellowblue 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. The shoulder belt is too loose. It won’t give nearly as much protection this way.
Page 18 yellowblue 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.
Page 19 yellowblue 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 20 yellowblue 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 21: Safety Belt Use During Pregnancy
yellowblue Safety Belt Use During Pregnancy Safety belts work for everyone, including pregnant women. Like all occupants, they are more likely to be seriously injured if they don’t wear safety belts. To unlatch the belt, just push the button on the buckle. The belt should go back out of the way.
Page 22: Right Passenger Position
yellowblue The best way to protect the fetus is to protect the Lap Belt mother. When a safety belt is worn properly, it’s more If your vehicle has a center seat, someone can sit in the likely that the fetus won’t be hurt in a crash. For center position.
Page 23 yellowblue Buckle, position and release it the same way as the lap part of a lap shoulder belt. 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.
Page 24: Smaller Children And Babies
yellowblue Smaller Children and Babies Infants need complete support, including support for the head and neck. This is necessary because an infant’s neck is weak and its head weighs so much compared with the rest of its body. In a frontal crash, CAUTION: an infant in a rear facing restraint settles into the...
Page 25 yellowblue CAUTION: Never hold a baby in your arms while riding in a vehicle. A baby doesn’t weigh much until a crash. During a crash a baby will become so heavy you can’t hold it. For example, in a crash at only 25 mph (40 km/h), a 12 lb.
Page 26: Child Restraints
yellowblue Child Restraints Every time infants and young children ride in vehicles, they should have protection provided by appropriate restraints. What are the different types of add child restraints? on child restraints are available in four basic types. When selecting a child restraint, take into consideration not only the child’s weight and size, but also whether or not the restraint will be compatible with the motor vehicle in which it will...
Page 27 yellowblue An infant car bed (A) is a special bed made for use A rear facing infant restraint (B) positions an infant in a motor vehicle. It’s an infant restraint system to face the rear of the vehicle. Rear facing infant designed to restrain or position a child on a restraints are designed for infants of up to about continuous flat surface.
Page 28 yellowblue 1-22...
Page 29 yellowblue A forward facing child restraint (C E) positions a child upright to face forward in the vehicle. These forward facing restraints are designed to help protect children who are from 20 to 40 lbs. (9 to 18 kg) and about 26 to 40 inches (66 to 102 cm) in height, or up to around four years of age.
Page 30: Top Strap
yellowblue When choosing a child restraint, be sure the child restraint is designed to be used in a vehicle. If it is, it will have a label saying that it meets federal motor vehicle safety standards. Then follow the instructions for the restraint. You may find these instructions on the restraint itself or in a booklet, or both.
Page 31 yellowblue Securing a Child Restraint in the Center Seat Position (If Equipped) If your vehicle has a center seat, you can secure a child restraint here. You’ll be using the lap belt. Be sure to follow the 1. Make the belt as long as possible by tilting the latch instructions that came with the child restraint.
Page 32 yellowblue 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 restraint as you tighten the belt.
Page 33: Larger Children
yellowblue Larger Children If you have the choice, a child should sit next to a window so the child can wear a lap shoulder belt and get the additional restraint a shoulder belt can provide. Children who aren’t buckled up can be thrown out in a crash.
Page 34 yellowblue 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.
Page 35 yellowblue 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 36: Safety Belt Extender
yellowblue 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 37: Section 2 Features And Controls
yellowblue 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 38 yellowblue 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 controls or even make the vehicle move. Don’t leave the keys in a vehicle with children.
Page 39: Door Locks
yellowblue One key operates all locks, including the ignition switch. Door Locks The key has a code on it that tells your dealer or a qualified locksmith how to make extra keys. Record the CAUTION: key code in a safe place. If you lose your keys, you’ll be able to have new ones made easily using this code.
Page 40: Key In The Ignition
yellowblue Theft Vehicle theft is big business, especially in some cities, and even commercial vehicles are no exception. Although your vehicle has a number of theft deterrent features, we know that nothing we put on it can make it impossible to steal. However, there are ways you can help.
Page 41 yellowblue 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 42: Ignition Positions
yellowblue Ignition Positions LOCK: This position lets you insert and remove the ignition key. ACC (Accessory): This position lets you use CAUTION: accessories when the engine is off. ON: This is the position for driving. Leaving children in a vehicle with the ignition START: This position starts your engine.
Page 43: Starting Your Gasoline Engine
yellowblue Starting Your Gasoline Engine Starter Motor Operation 1. The starter motor will disengage if you release Engines start differently. The 8th digit of your Vehicle the key or the engine reaches a predetermined Identification Number (VIN) shows the code letter for engine speed.
Page 44: Starting Your Engine
yellowblue Starting Your Engine NOTICE: 1. Without pushing the accelerator pedal, turn your ignition key to START. When the engine starts, let Your engine is designed to work with the go of the key. The idle speed will go down as your electronics in your vehicle.
Page 45: Starting Your Diesel Engine
yellowblue Restarting the Gasoline Engine While While your engine is idling before you turn it off, you can make a list of any operational or handling concerns Moving (Automatic Transmission) to give to responsible maintenance personnel so they can If you have to restart the engine while the vehicle is handle them right away.
Page 46: Stopping The Diesel Engine
yellowblue Restarting the Diesel Engine While Moving NOTICE: (Automatic Transmission) If you have to restart the engine while the vehicle is Your diesel engine has an electric air intake moving, you’ll first have to shift the automatic heater system which reduces white smoke and transmission to NEUTRAL (N).
Page 47 yellowblue Cold Weather Starting The five beats per second tone alarm means that your diesel engine will shut down in 25 seconds. Pull off the (Caterpillar Diesel) road and shut off the engine. Don’t start it until the Because the diesel engine uses compression ignition, it reason for the problem is known, and the problem is is harder to start in cold weather than a gasoline engine.
Page 48: Fast Idle System
yellowblue Fast Idle System Manual Fast Idle System Your vehicle is equipped with an electronically The manual fast idle system controlled diesel engine. It has both automatic and includes a switch and an manual fast idle capabilities. indicator light. The switch is located to the right of the Automatic Fast Idle System comfort controls on the...
Page 49 yellowblue Starting Your DURAMAX t DIESEL The manual fast idle feature is activated by pressing the switch on the instrument panel. When manual fast idle is Engine engaged, the indicator lamp will illuminate. When the switch is pressed again, or any of the above conditions 1.
Page 50 yellowblue 6. Release the key the instant the engine starts. NOTICE: 7. After the engine starts, check to make sure the transmission is still in NEUTRAL (N), and release If the engine control switch is held in the “H” the clutch pedal. position after the indicator glows red, the glow 8.
Page 51 yellowblue Avoid Unnecessary Idling of the 2. Observe the engine coolant temperature gage. If the gage reaches the hot area, stop the engine Diesel Engine and determine the cause of overheating. If the engine idles too long, the temperature of the 3.
Page 52: Stopping The Engine
yellowblue 5. Observe the voltmeter. The voltmeter is calibrated in Stopping the Engine volts. During operation, the indicator hand should remain in the 13 to 15 volt range to indicate normal NOTICE: battery condition. If the indicator remains at less than normal voltage, an undercharge condition exists.
Page 53: Engine Checks Before Operating
yellowblue Engine Checks Before Operating The charging system light should come on when the ignition switch key is turned to ON or START and When you’ve started your engine, let it run for should go out when the engine is running above idle. 20 to 30 seconds before you put a load on the engine.
Page 54: To Use The Engine Coolant Heater
yellowblue To Use the Engine Coolant Heater NOTICE: 1. Turn off the engine. 2. Find the plug in receptacle (either behind the front Don’t allow the engine to operate at low idle for bumper or in the component box). more than five minutes. This can cause low 3.
Page 55: Diesel Engine Exhaust Brake
yellowblue How long should you keep the coolant heater plugged Diesel Engine Exhaust Brake in? The answer depends on the outside temperature. Above 32 _ F (0 _ C), the coolant heater is not required. The exhaust brake is available on vehicles equipped From 32 _ F to 10 _ F (0 _ C to 23 _ C), keep the coolant...
Page 56 yellowblue When using the exhaust brake, the proper gear range selection is important. The exhaust brake will be most CAUTION: effective if the gear range selected is the lowest possible range that does not allow the engine rpm to go more Be careful when using the exhaust brake or you than 200 rpm above the rated (full load) rpm as could lock the wheels and lose control of the...
Page 57: Automatic Transmission
yellowblue Speed Rear Axle Electric Shift Automatic Transmission Control (If Equipped) The switch is located on the instrument panel to the right of the comfort controls. When the switch is up, the rear axle is in the high range. Push it down to get the low range. The two speed axle should be in low range when you park the vehicle.
Page 58: Manual Transmission
yellowblue Under light load conditions, first shift the axle into the Air Suspension (If Equipped) high range with the vehicle at a standstill and then Your vehicle may be equipped with the Hendrickson operate the transmission normally. HAS Series single axle air suspension which is designed for single axle on...
Page 59: Automatic Transmission Operation
yellowblue The switch to deflate and inflate the air suspension is CAUTION: located on the instrument panel to the right of the It can be dangerous to get out of your vehicle comfort controls. without the parking brake firmly set. Your vehicle can roll.
Page 60: Manual Transmission Operation
yellowblue Automatic Transmission Third Gear Hold Double-Clutching (If Equipped) You must use the “double clutching” method when you shift an unsynchronized gear set. Simply disengage the If your vehicle has this feature, your range selector has a clutch, shift to NEUTRAL and engage the clutch. When “2 3”...
Page 61: Two-Speed Rear Axle
yellowblue Eaton Fuller 9- and 10-Speed Transmissions Parking If your vehicle has one of these unsynchronized transmissions, it’s naturally somewhat complicated. The CAUTION: label above the windshield will tell you the operating basics you need to know. If you don’t park your vehicle properly, it can Before operating the vehicle with one of these roll.
Page 62: Hydraulic Brakes
yellowblue Hydraulic Brakes Lever Operated Parking Brake If your vehicle has hydraulic brakes, it has a parking To apply the parking brake, pull the lever all the way up. brake lever or an electric/hydraulic parking brake. The The PARK BRAKE light will come on when the parking lever is below the instrument panel to the left of the brake is applied.
Page 63 yellowblue If your parking brake doesn’t hold the vehicle when Electric/Hydraulic Parking Brake applied, see your GM Truck dealer who can adjust your (If Equipped) parking brake properly. To release the parking brake, first push down the regular CAUTION: brake pedal. Then, push the parking brake lever all the way down and shift the transmission to NEUTRAL (N).
Page 64 yellowblue If your vehicle has this The PARK BRAKE light may flash while the parking system, you will have a brake is being applied or released. This is normal for knob to the right of this system. the driver. If your vehicle needs towing and the parking brake will not release, the towing operator will need to disconnect the propshaft before towing your vehicle.
Page 65 yellowblue Vehicles built for use as tractors and/or towing vehicles may also have these controls. They look like this: If your vehicle has air brakes, you may have these controls. To charge a trailer’s air brake system: Pulling the yellow button out applies the parking brake. Move your tractor into the proper position.
Page 66 yellowblue If you have the TRACTOR PARKING (blue) knob, pull If the air pressure drops below 60 to 70 psi it out to set the tractor brakes while the air system (413 to 482 kPa), the PRIMARY BRAKE light will is charging.
Page 67: Parking Over Things That Burn
yellowblue 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 68: Running Your Engine While You're Parked (Automatic Transmission)
yellowblue Running Your Engine While You’re CAUTION: Parked (Automatic Transmission) It’s better not to park with the engine running. But if It can be dangerous to get out of your vehicle ever you have to, here are some things to know. without the parking brake firmly set.
Page 69: Passenger Side Door Glass
yellowblue Windows Passenger Side Door Glass The window controls are on each door. The driver’s door has a switch for the passenger’s window and a LOCK button as well. When the LOCK button has been pushed down, the passenger’s side window will not operate with either window control The passenger’s side door window opens to allow the switch.
Page 70: Tilt Steering Column
yellowblue To tilt the column, hold the steering wheel and pull the CAUTION: lever on the left side of the column up to unlock the Never open the passenger side door glass with the steering column. ignition in ON. You can be injured if the window linkage moves.
Page 71: Turn Signal/Multifunction Lever
yellowblue Turn Signal/Multifunction Lever Turn Signal and Lane Change Indicator 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.
Page 72 yellowblue If a bulb is burned out, replace it to help avoid an Headlamps On Reminder (If Equipped) accident. If the arrows don’t go on at all when you If you have this system, a tone alarm will sound when signal a turn, check the circuit breaker for burned your headlamps and/or parking lamps are turned on and bulbs.
Page 73: Windshield Wipers
yellowblue Windshield Wipers You can set the wiper speed for a long or short delay between wipes. This can be very useful in light rain or snow. To operate the delay wipers, turn the knob at the end of the stalk to INT. Then turn the INT TIME band to choose the delay time.
Page 74: Trailer Brake Hand Control Valve
yellowblue Trailer Brake Hand Control Valve CAUTION: (Option) If your vehicle has this Using the trailer brake hand control for parking or control, it is mounted on the for holding the vehicle on a hill may not keep the console to the right of the vehicle from rolling.
Page 75: Inter - Axle Differential Lock Control
yellowblue Inter Axle Differential Lock Control Hand Throttle Control (If Equipped) (If Equipped) If your vehicle has this feature, the control is located at the lower right corner of the instrument panel. If you’re approaching a slippery surface where it looks like one or even all of the wheels may start to slip, you can use this control.
Page 76: Exterior Lamps
yellowblue To use this feature, use the accelerator pedal to get the Exterior Lamps engine speed where you want it. Then, pull out the hand throttle control and turn the control clockwise. That sets Daytime Running Lamps (If Equipped) the engine speed. Daytime Running Lamps (DRL) can make it easier for To return the engine to its normal idle speed, push the others to see the front of your vehicle during the day.
Page 77 yellowblue When the DRL are on, only your low beam headlamps Marker and Clearance Lamps Switch will be on. The exterior lamps won’t be on. Your (If Equipped) instrument panel won’t be lit up either. Your vehicle will have this When it begins to get dark, your DRL indicator light is a switch only if it is designed reminder to turn your headlamp switch on.
Page 78: Interior Lamps
yellowblue Interior Lamps Mirrors Outside Mirrors Instrument panel light intensity is controlled by Adjust the outside mirror or this knob, located at the mirrors by hand so you can lower right portion of the just see the side of your instrument cluster.
Page 79: Heated Outside Mirrors (If Equipped)
yellowblue 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 the from the driver’s seat. switch on the instrument panel to the right of the comfort controls.
Page 80: Storage Compartments
yellowblue Storage Compartments Center Seat Storage (If Equipped) Overhead Storage A storage compartment is located behind the seatback in the center seat. To access the compartment, fold the seat An overhead storage compartment is provided above all the way forward. each of the driver’s and passenger’s seats.
Page 81: Ashtrays And Cigarette Lighter
yellowblue Then squeeze both Ashtrays and Cigarette Lighter sides of the latch to Ashtrays are provided at the front of each door. To open the compartment. remove the ashtray for cleaning, simply pull up on it. NOTICE: Don’t put papers and other things that burn into your ashtray.
Page 82: Sun Visors
yellowblue Sun Visors These jacks provide 12 volt power so you can operate things such as a citizen’s band (CB) radio or a cellular To block out glare, you can move down the sun visors. phone. You’ll see positive (red) and negative (black) You can also swing them from side to side.
Page 83: Air Connections
yellowblue Trailer Connections (If Equipped) NOTICE: These connections are located at the rear of the cab or vehicle. There is an air connection and a trailer Starting in 1998, the center pin (also known as electrical connection. the auxiliary circuit) of the 7 pin trailer electrical Be sure that all couplings to the trailer are connector will be wired to provide continuous...
Page 84: Instrument Panel
yellowblue Instrument Panel 2-48...
Page 85 yellowblue A. Turn Signal/Multifunction Lever I. Vents B. Vent J. Glovebox C. Instrument Panel Cluster K. Cigarette Lighter D. Warning Lights L. Audio System E. Windshield Wiper/Washer Controls M. Air Brake Controls (Option) F. Vents N. Horn G. Comfort Controls O.
Page 86: Instrument Panel Cluster
yellowblue Instrument Panel Cluster Your instrument 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. 2-50...
Page 87: Speedometer And Odometer
yellowblue Speedometer and Odometer Your odometer is tamper resistant. The odometer will show silver lines between the numbers if someone tries Your speedometer lets you see your speed in both miles to turn it back. per hour (mph) and kilometers per hour (km/h). You may wonder what happens if your vehicle needs a new odometer installed.
Page 88: Warning Lights, Gages And Indicators
yellowblue Tachometer Warning Lights, Gages and Indicators This part describes the warning lights and gages that 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 89: Safety Belt Reminder Light
yellowblue Safety Belt Reminder Light The charging system light is located in the center of the When the key is turned to instrument cluster just ON or START, a light will above the odometer. come on for about six seconds to remind people to fasten their safety belts.
Page 90 yellowblue Voltmeter If this light comes on while you are driving, do not use the transmission shift control. Using the transmission When your engine is shift control will result in the loss of forward gears. The running, the voltmeter gage, computer for the transmission senses a problem and at the lower left of the chooses a gear to stay in so that you can drive the...
Page 91: Brake System Warning Light
yellowblue Brake System Warning Light If the AUX BRAKE warning light comes on, Your vehicle has either hydraulic or air brakes. Each it means that there is system has different warning lights. something wrong in the auxiliary brake system. Hydraulic Brake System Warning Lights Vehicles with hydraulic systems have two brake system warning lights on the instrument panel.
Page 92 yellowblue When this warning light comes on, you will also hear a warning tone. If the warning light and tone come on CAUTION: while you are driving, you should drive only as far as the nearest point of safety and then stop the vehicle. Your brake system may not be working properly Here’s a very important thing for you to know: if a brake system warning light is on.
Page 93: Parking Brake Warning Light
yellowblue Apply Park Brake Warning Light When the SERVICE PARK BRAKE light comes on, you will also hear a warning tone. If this light comes on, This light warns the driver have the system repaired immediately. that the ignition has been turned off without applying the parking brake.
Page 94: Anti-Lock Brake System Warning Light
yellowblue The light will stay on if your parking brake doesn’t The anti lock brake system warning light should come release fully. on briefly when you turn the ignition key to ON. If the light doesn’t come on then, have it fixed so it will be This light should also come on when you turn the ready to warn you if there is a problem.
Page 95: Engine Coolant Temperature Gage
yellowblue Exhaust Brake Indicator Light If the gage pointer moves into the upper end of the temperature range, your engine coolant might have (Diesel Engines) overheated and your engine may be too hot. You should pull off the road, stop your vehicle and turn off the This light on the instrument engine as soon as possible.
Page 96: Low Coolant Warning Light
yellowblue Low Coolant Warning Light Manual Fast Idle Indicator Light (If Equipped) You have a LOW COOLANT warning light. If your vehicle is equipped If this light comes on, your with an electronically system is low on coolant controlled diesel engine, and the engine you have this indicator may overheat.
Page 97 yellowblue Intake Heater Indicator Light Diff Lock Indicator Light (If Equipped) (Diesel Engines) This light on the instrument panel is on when the This light on the instrument inter axle differential lock panel will come on when system is in use. the intake heater is on and the ignition switch is in ON.
Page 98: Engine Oil Pressure Gage
yellowblue Malfunction Indicator Lamp NOTICE: (Service Engine Soon Light) If your vehicle is equipped with either a gasoline engine If you keep driving your vehicle with this light or an electronically controlled diesel engine, you will on, after a while, your emission controls may not have this light.
Page 99 yellowblue A reading in the low pressure zone may be caused by a Change Oil Light (If Equipped) dangerously low oil level or other problem. The CHANGE OIL light If you have a diesel engine, also see your Caterpillar should come on briefly as a Operation &...
Page 100: Engine Overspeed Warning Light
yellowblue Engine Overspeed Warning Light Check Gages Indicator Light (If Equipped) If your vehicle has a This light will come on as gasoline engine, you’ll you’re starting the engine, have this light on the just as a check. instrument panel. If it comes on when you’re driving, it means that your If it ever comes on and stays on while you are driving, engine speed is too great.
Page 101: Fuel Gage
yellowblue Fuel Gage Here are four concerns of some operators. None of these shows a problem with your fuel gage: When the ignition is on, The gage moves a little when you turn a corner or your fuel gage lets you speed up.
Page 102 yellowblue Air Pressure Gage (If Equipped) The top pointer shows the pressure available for the front system, while the bottom pointer shows pressure If your vehicle has air for the rear. There should be no more than 4 psi (28 kPa) brakes, this gage shows the difference showing between the systems.
Page 103: Section 3 Comfort Controls And Audio Systems
yellowblue 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 FM Stereo Heating/Air Conditioning Controls FM Stereo with Cassette Tape Player...
Page 104: Comfort Controls
yellowblue Comfort Controls HEATER: Press this button to make all of the airflow come through the floor outlets. Heating/Air Conditioning Controls DEFROST/HEATER: This button makes air come out of both the bottom of the windshield area and near the floor. DEFROST: This setting operates the defroster.
Page 105: Air Conditioning (If Equipped)
yellowblue Heating Air Conditioning (If Equipped) On cold days, use the fan control lever with the When you first turn on your vehicle’s air conditioning, temperature selector all the way toward the red area. open the windows long enough to clear the vehicle of When the inside of the vehicle has reached a hot air, then close them.
Page 106: Ventilation System
yellowblue Ventilation System Ventilation Tips Keep the front air inlet free of ice, snow or any other obstruction (such as leaves). The heater and defogger will work better, reducing the chance of fogging the inside of your windows. When you enter a vehicle in cold weather, turn the blower fan to 4 for a few moments before driving off.
Page 107: Audio Systems
yellowblue Audio Systems AM-FM Stereo Your audio system has been designed to operate easily and give years of listening pleasure. You will get the most enjoyment out of it if you acquaint yourself with it first. Find out what your audio system can do and how to operate all its controls, to be sure you’re getting the most out of the advanced engineering that went into it.
Page 108 yellowblue Finding a Station preset scan scans from the next station. It will scan through each station stored on your pushbuttons and BND: Pressing this button will alternately select either stop for five seconds before continuing to scan through the AM or the FM band. The selected band will be all of the pushbuttons.
Page 109 yellowblue Setting the Tone Using the Alarm TONE: Turn the control behind the ON/VOL knob ALARM: The alarm in your radio can be used to clockwise to emphasize the treble and counterclockwise activate an alarm at a desired time. to emphasize the bass. To set the timer, press the DISP button to switch the display to ALARM.
Page 110: Am-Fm Stereo With Cassette Tape Player (If Equipped)
yellowblue Setting the Wake Up Timer AM-FM Stereo with Cassette Tape Player (If Equipped) The wake up timer can be used to turn the radio on at a specific time without the key in the ignition. Press the DISP button. While the alarm symbol flashes, press the alarm button so that the display shows the letter U.
Page 111 yellowblue Finding a Station PUSHBUTTONS: The five numbered preset buttons let you return to your favorite stations. You can set up to AM FM: Pressing this button will alternately select 10 stations (five AM and five FM). Just: either the AM or the FM band. The selected band will be indicated on the display.
Page 112 yellowblue Using the Alarm Playing a Cassette Tape ALARM: The alarm in your radio can be used to Your tape player is built to work best with tapes that are 30 to 45 minutes long on each side. Tapes longer than activate an alarm at a desired time.
Page 113: Understanding Radio Reception
yellowblue Understanding Radio Reception To help avoid hearing loss or damage: Adjust the volume control to the lowest setting. Increase volume slowly until you hear comfortably The range for most AM stations is greater than for FM, and clearly. especially at night. The longer range, however, can cause stations to interfere with each other.
Page 114: Care Of Your Cassette Tape Player
yellowblue 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 115 yellowblue NOTES 3-13...
Page 116 yellowblue NOTES 3-14...
Page 117: Section 4 Your Driving And The Road
yellowblue 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 118: Defensive Driving
yellowblue 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.
Page 119: Drunken Driving
yellowblue Drunken Driving The obvious way to solve the leading highway safety problem is for people never to drink alcohol and then Death and injury associated with drinking and driving is drive. But what if people do? How much is “too much” if a national tragedy.
Page 120 yellowblue Since alcohol is carried in body water, this means that a woman generally will reach a higher BAC level than a man of her same body weight when each has the same number of drinks. The law in many U.S. states sets the legal limit at a BAC of 0.10 percent.
Page 121 yellowblue The body takes about an hour to rid itself of the alcohol in one drink. No amount of coffee or number of cold CAUTION: showers will speed that up. “I’ll be careful” isn’t the right answer. What if there’s an emergency, a need to Drinking and then driving is very dangerous.
Page 122: Control Of A Vehicle
yellowblue 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 123: Hydraulic Brake Systems
yellowblue Avoid needless heavy braking. Some people drive in Hydraulic Brake Systems spurts heavy acceleration followed by heavy If your engine stops running, or if your primary brake braking rather than keeping pace with traffic. This is a system stops working, your vehicle has a reserve power mistake.
Page 124 yellowblue Anti-Lock Brakes (Option) Your vehicle may have anti lock brakes (ABS). ABS is an advanced electronic braking system that will help prevent a braking skid. If your vehicle has anti lock brakes, this warning light on the instrument panel will come on briefly when you start your vehicle.
Page 125 yellowblue The anti lock system can change the brake pressure faster Remember: Anti lock doesn’t change the time you need than any driver could. The computer is programmed to to get your foot up to the brake pedal or always decrease make the most of available tire and road conditions.
Page 126: Braking In Emergencies
yellowblue Braking in Emergencies Steering At some time, nearly every driver gets into a situation Power Steering that requires hard braking. If you lose power steering assist because the engine If you have anti lock, you can steer and brake at the stops or the system is not functioning, you can steer but same time.
Page 127: Steering In Emergencies
yellowblue The traction you can get in a curve depends on the If you need to reduce your speed as you approach a condition of your tires and the road surface, the angle at curve, do it before you enter the curve, while your front which the curve is banked, and your speed.
Page 128: Off Road Recovery
yellowblue Road Recovery You may find that your right wheels have dropped off the edge of a road onto the shoulder while you’re driving. An emergency like this requires close attention and a quick decision. If you are holding the steering wheel at the recommended 9 and 3 o’clock positions, you may be able to turn it just enough to miss the object without removing either hand.
Page 129 yellowblue Passing Watch for traffic signs, pavement markings and lines. If you can see a sign up ahead that might indicate a The driver of a vehicle about to pass another on a turn or an intersection, delay your pass. A broken lane highway waits for just the right moment, center line usually indicates it’s all right to pass accelerates, moves around the vehicle ahead, then goes...
Page 130: Loss Of Control
yellowblue If other cars are lined up to pass a slow vehicle, wait Loss of Control your turn. But take care that someone isn’t trying to Let’s review what driving experts say about what pass you as you pull out to pass the slow vehicle. happens when the three control systems (brakes, steering Check your mirrors and start your left lane change and acceleration) don’t have enough friction where the...
Page 131: Driving At Night
yellowblue Of course, traction is reduced when water, snow, ice, Driving at Night gravel or other material is on the road. For safety, you’ll want to slow down and adjust your driving to these conditions. It is important to slow down on slippery surfaces because stopping distance will be longer and vehicle control more limited.
Page 132: Night Vision
yellowblue Here are some tips on night driving. You can be temporarily blinded by approaching headlamps. It can take a second or two, or even several Drive defensively. seconds, for your eyes to readjust to the dark. When you Don’t drink and drive. are faced with severe glare (as from a driver who doesn’t lower the high beams, or a vehicle with Since you can’t see as well, you may need to...
Page 133: Driving In Rain And On Wet Roads
yellowblue 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 134 yellowblue CAUTION: Wet brakes can cause accidents. They won’t work as well in a quick stop and may cause pulling to one side. You could lose control of the vehicle. After driving through a large puddle of water or a vehicle wash, apply your brake pedal lightly until your brakes work normally.
Page 135: Driving Through Deep Standing Water
yellowblue 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 or it has little or no contact with the road.
Page 136: City Driving
yellowblue 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 137: Freeway Driving
yellowblue 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 138: Highway Hypnosis
yellowblue Once you are moving on the freeway, make certain you When you drive the vehicle for a long distance, there is allow a reasonable following distance. Expect to move something about an easy stretch of road with the same slightly slower at night.
Page 139: Hill And Mountain Roads
yellowblue Hill and Mountain Roads Here are some tips that can make your drive through steep country safer: Keep the vehicle in good shape. Check all fluid levels and also the brakes, tires, cooling system and transmission. These parts can work hard on mountain roads.
Page 140: Winter Driving
yellowblue Winter Driving CAUTION: Coasting downhill in NEUTRAL (N) or with the ignition off is dangerous. Your brakes will have to do all the work of slowing down. They could get so hot that they wouldn’t work well. You would then have poor braking or even none going down a hill.
Page 141: Driving On Snow Or Ice
yellowblue 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 142 yellowblue Whatever the condition smooth ice, packed, blowing Remember, unless you have anti lock, if you brake so or loose snow drive with caution. hard that your wheels stop rolling, you’ll just slide. Brake so your wheels always keep rolling and you Accelerate gently.
Page 143: If You're Caught In A Blizzard
yellowblue 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 144 yellowblue 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 keeps the Snow can trap exhaust gases under your vehicle.
Page 145: Loading Your Vehicle
yellowblue Loading Your Vehicle The Certification/Tire label is provided by the final manufacturer and should be on the door or door jamb. It The GVW/Tire Information label is found on the rear also tells you the maximum weights for the front and rear edge of the driver’s door.
Page 146 yellowblue Using heavier suspension components to get added durability might not change your weight ratings. Ask CAUTION: your dealer or the body installation company to help you load your vehicle the right way. Things you put inside your vehicle can strike and injure people in a sudden stop or turn, or in NOTICE: a crash.
Page 147 yellowblue Power Take Off (PTO) (If Equipped) 4. Move the PTO switch to ON. This sets the PTO base idle at 1200 rpm. Before using a PTO, refer to the body builder’s or 5. Use the PTO rocker switch to change the engine operator’s instructions.
Page 148 yellowblue NOTES 4-32...
Page 149: Section 5 Problems On The Road
yellowblue 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 (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 150: Hazard Warning Flashers
yellowblue Hazard Warning Flashers Move the lever up on the right side of the steering column to start the hazard flashers. Move the lever down again to turn the flashers off. Your hazard warning flashers work no matter what position your key is in, and even if the key isn’t in. Also, when the hazard warning flashers are on, your turn Your hazard warning flashers let you warn others.
Page 151: Other Warning Devices
yellowblue Other Warning Devices CAUTION: If you carry reflective triangles, you can set one up at the side of the road behind your vehicle in the recommended manner per FMCSR (Federal Motor Carrier Safety Batteries can hurt you. They can be Regulation) Section 392.22, to warn others.
Page 152 yellowblue 1. Check the other vehicle. It must have a 12 volt battery with a negative ground system. CAUTION: NOTICE: Ignoring these steps could result in costly damage to your vehicle that wouldn’t be covered by your warranty. If the other system isn’t a 12 volt system with a negative ground, both vehicles can be damaged.
Page 153 yellowblue 3. Turn off the ignition on both vehicles. Turn off all lamps that aren’t needed, as well as radios. This will CAUTION: avoid sparks and help save both batteries, and it could save your radio. Using a match near a battery can cause battery gas to explode.
Page 154 yellowblue 5. Check that the jumper cables don’t have loose or 6. Connect the red missing insulation. If they do, you could get a shock. positive (+) cable to the The vehicles could be damaged, too. positive (+) terminal of the vehicle with the Before you connect the cables, here are some basic dead battery.
Page 155 yellowblue 8. Now connect the black 9. Attach the cable at least negative ( ) cable to the 18 inches (45 cm) away good battery’s from the dead battery, negative ( ) terminal. but not near engine parts that move. The electrical connection is just as good there, but the chance of sparks getting...
Page 156: Towing Your Vehicle
yellowblue Towing Your Vehicle Try to have a GM dealer or a professional towing service tow your vehicle. They can provide the right equipment and know how to tow it without damage. Before you do anything, turn on the hazard warning flashers (if they have not been damaged).
Page 157 yellowblue Towing Your Vehicle From the Front CAUTION: (Front Wheels Off the Ground) Before Towing To help avoid injury to you or others: Block the rear wheels of the disabled vehicle. On Never let passengers ride in a vehicle that is vehicles with air brakes, release the emergency brake being towed.
Page 158 yellowblue Towing the Vehicle with the Front Bumper Removed Rear Axle (Single and Tandem Drive) 1. Remove the front bumper. For single drive rear axles, disconnect the propshaft at the rear axle. For tandem rear axles, disconnect the 2. Connect and lock the lift chains to the front axle, propshaft from the forward axle.
Page 159 yellowblue Before Towing Towing Your Vehicle From the Rear (Rear Wheels Off the Ground) Block the wheels of the disabled vehicle. On vehicles with air brakes, release the emergency brake system by Before Towing compressing the brake chamber springs as outlined in this section.
Page 160 yellowblue 1. Block the wheels of the vehicle. CAUTION: Working on air brakes without first using the release studs to compress the springs can lead to injury. Never work on the air brake chambers without first using the release studs to compress the brake springs. When the brake springs are manually compressed, you will have no brakes.
Page 161 yellowblue 3. Remove the rubber cap 6. Using a 3/4 wrench, from the rear of turn the stud nut the chamber. clockwise 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 162: Engine Overheating
yellowblue Engine Overheating CAUTION: You will find a coolant temperature warning gage and a CHECK GAGES warning light on your vehicle’s instrument panel. If you have a diesel engine, there will Steam from an overheated engine can burn you also be a LOW COOLANT warning light. badly, even if you just tilt the cab.
Page 163: If No Steam Is Coming From Your Engine
yellowblue 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 10 minutes. If you get an engine overheat warning but see or hear no If the warning doesn’t come back on, you can steam, the problem may not be too serious.
Page 164: Cooling System (Gasoline Engine)
yellowblue Cooling System (Gasoline Engine) The coolant level should be at COLD FULL. When you decide it’s safe to check the coolant level at the back of the cab, you’ll see the coolant recovery tank. If it isn’t, you may have a leak in the radiator hoses, heater hoses, radiator, water pump or somewhere else in the cooling system.
Page 165 yellowblue NOTICE: CAUTION: When adding coolant, it is important that you use Heater and radiator hoses, and other engine only DEX COOL (silicate free) coolant. parts, can be very hot. Don’t touch them. If you If coolant other than DEX COOL is added to the do, you can be burned.
Page 166: Recovery Tank
yellowblue How to Add Coolant to the Coolant NOTICE: Recovery Tank If you haven’t found a problem yet, but the coolant level In cold weather, water can freeze and crack the isn’t at COLD FULL, add a 50/50 mixture of clean, engine, radiator, heater core and other parts.
Page 167 yellowblue When the coolant in the coolant recovery tank is CAUTION: at COLD FULL, start your vehicle. 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 enough.
Page 168 yellowblue 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 169: How To Add Coolant To The Radiator
yellowblue How to Add Coolant to the Radiator 2. Then keep turning the pressure cap, but now 1. You can remove the push down as you turn radiator pressure cap it. Remove the when the cooling pressure cap. system, including the radiator pressure cap and upper radiator hose, is no longer hot.
Page 170 yellowblue 4. Then fill the coolant recovery tank to COLD FULL. 5. Put the cap back on the coolant recovery tank, but leave the pressure cap off. 3. Fill the radiator with the proper DEX COOL coolant mixture, up to the base of the filler neck. (See “Engine Coolant”...
Page 171 yellowblue 6. Start the engine and let it 8. Then replace the run until you can feel the pressure cap. At any upper radiator hose time during this getting hot. Watch procedure if coolant out for the engine begins to flow out of the cooling fan.
Page 172 yellowblue Cooling System (Diesel Engine) The coolant level should be at COLD FULL or higher. When you decide it’s safe to check the coolant level at If it isn’t, you may have a the back of the cab, you’ll see the coolant surge tank. leak in the radiator hoses, heater hoses, radiator, water pump or somewhere else in...
Page 173: How To Add Coolant To The Coolant Surge Tank
yellowblue How to Add Coolant to the Coolant NOTICE: Surge Tank If you haven’t found a problem yet, but the coolant level Engine damage from running your engine isn’t at COLD FULL, add a 50/50 mixture of clean, without coolant isn’t covered by your warranty. drinkable water and coolant at the coolant surge tank, but be sure the cooling system, including the coolant surge tank pressure cap, is cool before you do it.
Page 174 yellowblue 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 175 yellowblue NOTICE: CAUTION: In cold weather, water can freeze and crack the Adding only plain water to your cooling system engine, radiator, heater core and other parts. So can be dangerous. Plain water, or some other use the recommended coolant. liquid like alcohol, can boil before the proper coolant mixture will.
Page 176 yellowblue 1. You can remove the coolant surge tank pressure cap 2. Then keep turning the cap, but now push down as when the cooling system, including the coolant surge you turn it. Remove the pressure cap. tank pressure cap and upper radiator hose, is no longer hot.
Page 177 yellowblue 3. Then fill the coolant By this time, the coolant level inside the coolant surge surge tank with the tank may be lower. If the level is lower, add more of the proper coolant mixture, proper mixture to the coolant surge tank until the level up to COLD FULL.
Page 178: Engine Fan Noise
yellowblue Engine Fan Noise If a Tire Goes Flat Your vehicle has a clutched engine cooling fan. When It’s unusual for a tire to “blow out” while you’re driving, the clutch is engaged, the fan spins faster to provide especially if you maintain your tires properly. If air goes more air to cool the engine.
Page 179: Changing A Flat Tire
yellowblue Changing a Flat Tire CAUTION: A flat or damaged tire can be a major roadside problem. You’re very likely to have to go for help. Few drivers of these vehicles have the necessary equipment aboard to Tire rim assemblies can explode. If you work on be able to change a flat tire safely.
Page 180 yellowblue CAUTION: CAUTION: If you work on a pressurized tire mounted on a Rust or dirt on the wheel, or on the parts to damaged wheel, the assembly can expand with which it is fastened, can make the wheel nuts explosive force without warning.
Page 181 yellowblue If the lock ring and side rings seem to be seated properly (or if the wheel doesn’t have these), let the CAUTION: air out of the tire. You can do this by taking out the valve core. There are many ways to be hurt badly, or If the flat or damaged tire is one of a dual set, let the be killed, while you are trying to change a air out of both tires of the dual before you take off...
Page 182: If You're Stuck: In Sand, Mud, Ice Or Snow
yellowblue Use a clip on chuck and hose extension when you NOTICE: add air to your tires. You’ll need an accurate truck tire pressure gage. Stand to one side and add the air. Be sure you don’t go over the top inflation pressure Improperly tightened wheel nuts can lead to for the tire.
Page 183: Rocking Your Vehicle To Get It Out
yellowblue Rocking Your Vehicle To Get It Out CAUTION: First, turn your steering wheel left and right. That will clear the area around your front wheels. Then shift back and forth between REVERSE (R) and a forward gear If you let your tires spin at high speed, they can (or with a manual transmission, between FIRST (1) or explode, and you or others could be injured.
Page 184 yellowblue NOTES 5-36...
Page 185 yellowblue NOTES 5-37...
Page 186 yellowblue NOTES 5-38...
Page 187: Section 6 Service And Appearance Care
yellowblue 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 188: Doing Your Own Service Work
yellowblue 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.
Page 189: Two Safety Cautions About Engine Fan Breakage
yellowblue Two Safety Cautions about Engine CAUTION: Fan Breakage You can be injured and your vehicle could be CAUTION: damaged if you try to do service work on a vehicle without knowing enough about it. Changing the Fan Drive Ratio or Engine Be sure you have sufficient knowledge, Governed Speed experience, the proper replacement parts...
Page 190: Fuel (Gasoline Engine)
yellowblue Use regular unleaded gasoline rated at 87 octane or CAUTION: (Continued) higher. It is recommended that the gasoline meet specifications which have been developed by the Winter Fronts, Grille Covers or Obstructions American Automobile Manufacturers Association (AAMA) and endorsed by the Canadian Motor Vehicle Winter fronts, grille covers or other add Manufacturers Association for better vehicle equipment causing obstructions in front or...
Page 191: Diesel Fuel Requirements And Fuel System
yellowblue Some gasolines that are not reformulated for low NOTICE: emissions may contain an octane enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask your service station operator whether or not Your vehicle was not designed for fuel that the fuel contains MMT. General Motors does not contains methanol.
Page 192: Fuels In Foreign Countries
yellowblue Fuels in Foreign Countries CAUTION: 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 Diesel fuel containing water is still flammable. recommended in the previous text on fuel.
Page 193: Filling Your Tank
yellowblue Filling Your Tank The fuel cap can be on either or both sides of your vehicle depending on option content. To take off the cap, turn it slowly to the left (counterclockwise). CAUTION: Gasoline Engine Vehicles: If you get gasoline on you and then something ignites it, you could be badly burned.
Page 194: Filling A Portable Fuel Container
yellowblue Filling a Portable Fuel Container NOTICE: CAUTION: If you need a new cap, be sure to get the right type. Your dealer can get one for you. If you get the wrong type, it may not fit or have proper Never fill a portable fuel container while it is in venting, and your fuel tank and emissions system your vehicle.
Page 195: Before You Tilt The Cab
yellowblue Cab Tilting Tilting the Cab To tilt the cab: Most fluids and lubricants requiring regular checking can be accessed at the back of the cab or under the hood 1. Locate the lever pin at the rear of the cab, on the access panel.
Page 196 yellowblue 4. Pull the secondary latch lever to release the hook from the catch at the back of the cab. The cab is now free to tilt. 3. Move the primary tilt lever all the way down. 6-10...
Page 197 yellowblue 6. Tilt the cab all the way forward until the cab support under the cab locks fully. A. Safety Lock Pin B. Cab Support 5. Using the handle located at the bottom of the cab at the back, rotate the cab forward. CAUTION: A cab not properly locked in the tilted position could fall, causing serious injury.
Page 198: Lowering The Cab
yellowblue 7. Remove the safety lock Lowering the Cab pin from its retainer on When the cab is ready to be lowered, follow the the cab support. Insert instructions below carefully. Before lowering the cab, be the pin into the hole in sure all filler caps are on properly.
Page 199 yellowblue 2. Squeeze the lever on the cab support to release the detent. 3. Using this handle located at the bottom of the cab toward the back, lower the cab until the hook catches and the cab is held down. 4.
Page 200: Lifting The Front Panel
yellowblue 5. Replace the pin and Lifting the Front Panel turn it to keep the To access the windshield washer fluid reservoir and the primary tilt lever from clutch fluid reservoir, the front panel must be lifted. moving downward. 1. To lift the panel, grasp the rear of the release catch, located at the bottom of the instrument...
Page 201: Noise Control System
yellowblue Noise Control System 2. Then go to the front of the vehicle and lift the The following information relates to compliance with panel at the center. Use Federal noise emission standards for vehicles with a the prop rod to hold the Gross Vehicle Weight Rating (GVWR) of more than panel open.
Page 202: Tampering With Noise Control System Prohibited
yellowblue Tampering With Noise Control Engine: System Prohibited Removal or rendering engine speed governor (if equipped) inoperative so as to allow engine speed to Federal law prohibits the following acts or the exceed manufacturer specifications. causing thereof: Fan and Drive: 1.
Page 203: Engine Oil (Gasoline Engine)
yellowblue Engine Oil (Gasoline Engine) Checking Engine Oil 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. Remove it again, get fuel.
Page 204: What Kind Of Engine Oil To Use
yellowblue Be sure to fill it enough to put the level somewhere in NOTICE: the proper operating range. Push the dipstick all the way back in when you’re through. Don’t add too much oil. If your engine has so What Kind of Engine Oil to Use much oil that the oil level gets above the upper Oils recommended for your vehicle can be identified by mark that shows the proper operating range,...
Page 205: Engine Oil Additives
yellowblue As shown in the chart, SAE 5W 30 is best for your vehicle. However, you can use SAE 10W 30 if it’s going to be 0 C) or above. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils, such as SAE 20W NOTICE: Use only engine oil with the American Petroleum...
Page 206: When To Change Engine Oil
yellowblue When to Change Engine Oil What to Do with Used Oil Your vehicle has a computer that lets you know when to Did you know that used engine oil contains certain change your engine oil. This is not based on mileage, elements that may be unhealthy for your skin and could but on engine revolutions and engine operating even cause cancer? Don’t let used oil stay on your skin...
Page 207: Engine Oil (Diesel Engines)
yellowblue Engine Oil Checking Engine Oil (Caterpillar Diesel Engines) Pull out the dipstick and clean it with a paper towel or a cloth, then push it back in all the way. Remove it again, See your Caterpillar Operation & Maintenance Manual keeping the tip down.
Page 208 yellowblue NOTICE: NOTICE: Don’t add too much oil. If your engine has so If you use oils that don’t have one of these much oil that the oil level gets above the proper designations, you can cause engine damage which operating range, your engine could be damaged.
Page 209 yellowblue This doughnut shaped logo (symbol) is used on most oil containers to help you select the correct oil. It means that the oil has been certified by the American Petroleum Institute. You should look for this on the oil container, and use only those oils that display the logo.
Page 210: Air Filter Restriction Indicator
yellowblue Engine Oil Additives Air Filter Restriction Indicator Don’t add anything to your oil. Your dealer is ready to Your engine has an indicator that lets you know when advise if you think something should be added. the air filter is dirty and needs to be serviced. It is in the air intake tube between the air cleaner and the When to Change Engine Oil turbocharger inlet...
Page 211: Engine Air Cleaner/Filter
yellowblue Engine Air Cleaner/Filter Your GM Maintenance Schedule says when to replace the air filter. Diesel Engine Gasoline Engine 6-25...
Page 212: Gasoline Engines
yellowblue Removing the Air Cleaner CAUTION: (Gasoline Engines) 1. To replace the air filter element on gasoline engines, Gasoline Engines Only: Operating the engine remove the finger screws holding the air cleaner cover. with the air cleaner/filter off can cause you or others to be burned.
Page 213: Air Conditioner Filter
yellowblue The air cleaner is located behind the cab on the Automatic Transmission Fluid passenger’s side. When to Check 1. To access the filter element, remove all three finger screws and carefully remove the cover. A good time to have it checked is when the engine oil is checked.
Page 214: Manual Transmission Fluid
yellowblue Automatic Transmission External Filter NOTICE: Your automatic transmission spin on type filter requires periodic replacement. It is mounted just behind the Too much or too little fluid can damage your radiator on the outside of the passenger’s side frame rail. transmission.
Page 215: How To Check Lubricant
yellowblue How to Check Lubricant Rear Axle Shift Motor (If Equipped) When to Check and Change Fluid If you have a controlled traction, or locking differential type rear axle, a good time to check the fluid level in the axle shift motor is when the rear axle lubricant is checked.
Page 216: Diesel Engine
yellowblue Surge Tank Pressure Cap Engine Coolant (Gasoline Engine) (Diesel Engine) The cooling system in your vehicle is filled with COOL engine coolant. This coolant is designed The surge tank pressure cap must be tightly installed to remain in your vehicle for 5 years or 150,000 miles with the arrows on the cap lined up with the top tube of (240 000 km), whichever occurs first, if you add only the coolant surge tank.
Page 217: What To Use
yellowblue NOTICE: CAUTION: When adding coolant, it is important that you Adding only plain water to your cooling system use only DEX COOL (silicate free) coolant. can be dangerous. Plain water, or some other If coolant other than DEX COOL is added to liquid like alcohol, can boil before the proper the system, premature engine, heater core or coolant mixture will.
Page 218: Checking Coolant
yellowblue Checking Coolant NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost wouldn’t be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts.
Page 219 yellowblue If this light comes on and stays on, it means you’re low on engine coolant. See “Lights, Low Coolant Warning Light” in the Index for further information. Coolant Recovery Tank (Gasoline Engines) The vehicle must be on a level surface. When your engine is cold, the coolant level should be at or above COLD FULL level on the coolant recovery tank.
Page 220 yellowblue 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 221: How To Check Power Steering Fluid
yellowblue 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 222: Windshield Washer Fluid
yellowblue 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 223: Hydraulic Clutch Fluid
yellowblue Hydraulic Clutch Fluid How to Check The proper fluid should be added if the fluid level is not The hydraulic clutch fluid between the MAX and MIN marks. reservoir is located behind the front panel on the Brakes driver’s side. Brake Fluid If your vehicle has hydraulic brakes, there’s a...
Page 224 yellowblue If it’s low, add enough fluid to fill the reservoir to the CAUTION: proper level. Don’t add brake fluid before you check the level. If you do, you could get too much brake fluid. Brake fluid could spill on the hot engine and it can catch fire.
Page 225 yellowblue Four-Wheel Disc Brakes (Hydraulic Only) CAUTION: Your vehicle has four wheel disc brakes. Some driving conditions or climates may cause a brake With the wrong kind of fluid in your brake squeal when the brakes are first applied or lightly system, your brakes may not work well, or they applied.
Page 226: Brake Pedal Travel
yellowblue Brake Pedal Travel Drain them at full system pressure. To be sure you’re See your dealer if the brake pedal does not return to at full pressure, check your normal height, or if there is a rapid increase in pedal air pressure gage.
Page 227 yellowblue Air Dryer (Option) Alcohol Injector (Option) If your vehicle has air brakes, it may have an air dryer. If your vehicle has air brakes, it may have an alcohol This collects and removes dirt, moisture or other foreign injector. It is on the frame or crossmember at the right matter from the air prior to entering the brake system.
Page 228: Replacing Brake System Parts
yellowblue To turn it on in cold Replacing Brake System Parts weather, turn the valve so The braking system on a vehicle is complex. Its many that the word ON is on top. parts have to be of top quality and work well together if When the temperature is the vehicle is to have really good braking.
Page 229: How To Check And Add Fluid
yellowblue Electric/Hydraulic Parking How to Check and Add Fluid Brake Fluid First, apply the parking brake. To check the fluid level, look at the MAX and MIN lines on the side of the If you have an electric/hydraulic parking brake, a good reservoir.
Page 230: Vehicle Storage
yellowblue Vehicle Storage Windshield Wiper Blade Replacement If you’re not going to drive your vehicle for 25 days or more, remove the black, negative ( ) cable from the battery. This will help keep your battery from running down. (If your vehicle has more than one battery, be sure to remove the negative ( ) battery cable from each battery.)
Page 231: Other Service Items
yellowblue Other Service Items Component Box Your vehicle has a component box along either frame rail. What is in the box depends on what options are on your vehicle. Normally, the fuel filter, air dryer, Luberfiner oil filter or other components are in there. Replacement blades come in different types and are removed in different ways.
Page 232 yellowblue To get into the box, you first have to remove the top cover. To do that, remove the two 8 mm bolts on top and the single 8 mm bolt at the top front. Then, pull the cover toward you and lift it off. You can then remove the front cover if you need to, by removing the two 8 mm bolts and pulling it off.
Page 233: Primary Fuel Filter And Water Separator
yellowblue Primary Fuel Filter and Water Separator Secondary Fuel Filter and Water (If Equipped) Separator/Heater (If Equipped) If you have a diesel engine, you may have this spin If you have a diesel engine, you may have this spin filter. It is located behind the cab on the driver’s side filter and fuel separator/heater.
Page 234: Front Wheel Bearings With Oil-Filled Hubs
yellowblue Automatic Ether Injection System Front Wheel Bearings with Oil-Filled Hubs (If Equipped) If your vehicle has oil filled If your diesel engine vehicle has this feature, the ether hubs, check occasionally to cylinder is mounted on the outside of the passenger’s see if they have enough oil.
Page 235: Air Conditioning System
yellowblue Air Conditioning System Muffler/Catalytic Converter Assemblies (Diesel Engines) Every now and then have your dealership check your air conditioning system to be sure it has not lost any cooling Some vehicles equipped with a Caterpillar diesel ability. If you think the system is not working properly, engine utilize a catalytic converter muffler assembly.
Page 236: Inflation -- Tire Pressure
yellowblue Inflation -- Tire Pressure CAUTION: The Certification/Tire label, which is on the driver’s door, shows the correct inflation pressures for your tires when they’re cold. “Cold” means your vehicle has been Poorly maintained and improperly used tires sitting for at least three hours or driven no more than are dangerous.
Page 237: Wheel Loading
yellowblue Wheel Loading NOTICE: (Continued) Wheels are stamped with a maximum load and cold inflation rating. Be sure you don’t exceed these. If you If your tires have too much air (overinflation), ever think you need to, first contact the rim and wheel you can get the following: maker to get their advice.
Page 238: When It's Time For New Tires
yellowblue CAUTION: CAUTION: If you operate your vehicle with a tire that is Mixing tires could cause you to lose control while badly underinflated, the tire can overheat. An driving. If you mix tires of different types like overheated tire can lose air suddenly or catch radial and bias belted tires the vehicle may not...
Page 239: Tightening The Wheel Nuts
yellowblue Tightening the Wheel Nuts 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 serious crash. All wheel nuts must be properly tightened. Follow the rules in this section to be sure they are.
Page 240 yellowblue Piloted Wheels, 8 Hole or 10 Hole 6. Tighten the nuts to 400 lb ft (542 N·m) if an The studs and nuts used with these wheels have eight hole stud or right hand threads. 480 lb ft (650 N·m) if a 1.
Page 241 yellowblue CAUTION: If wheel studs are damaged, they can break. If all the studs on a wheel broke, the wheel could come off and cause a serious crash. If any stud is damaged because of a loose running wheel, it could be that all of the studs are damaged.
Page 242: Wheel Replacement
yellowblue 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 243 yellowblue NOTICE: CAUTION: The wrong wheel can cause trouble in bearing Without the correct wheel, you may not be able life, brake cooling, speedometer/odometer to stop properly, and you could have other calibration, headlamp aim, bumper height, problems like a tire air out.
Page 244: Appearance Care
yellowblue 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 245: Special Fabric Cleaning Problems
yellowblue 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 246: Care Of Safety Belts
yellowblue Cleaning Vinyl CAUTION: Use warm water and a clean cloth. Rub with a clean, damp cloth to remove dirt. Do not bleach or dye safety belts. If you do, it You may have to do it more than once. may severely weaken them.
Page 247: Cleaning The Outside Of The Windshield And Wiper Blades
yellowblue Cleaning the Outside of the Cleaning the Outside of Your Vehicle Windshield and Wiper Blades The paint finish on your vehicle provides beauty, depth of color, gloss retention and durability. If the windshield is not clear after using the windshield washer, or if the wiper blade chatters when running, wax, Washing Your Vehicle sap or other material may be on the blade or windshield.
Page 248: Finish Care
yellowblue Cleaning Exterior Lamps/Lenses Foreign materials such as calcium chloride and other salts, ice melting agents, road oil and tar, tree sap, bird Use lukewarm or cold water, a soft cloth and a vehicle droppings, chemicals from industrial chimneys, etc., can washing soap to clean exterior lamps and lenses.
Page 249: Protecting Exterior Bright Metal Parts
yellowblue Protecting Exterior Bright Metal Parts Cleaning Tires Bright metal parts should be cleaned regularly to keep To clean your tires, use a stiff brush with a tire cleaner. their luster. Washing with water is all that is usually needed. However, you may use chrome polish on NOTICE: chrome or stainless steel trim, if necessary.
Page 250: Finish Damage
yellowblue Finish Damage Chemical Paint Spotting Any stone chips, fractures or deep scratches in the finish Some weather and atmospheric conditions can create a should be repaired right away. Bare metal will corrode chemical fallout. Airborne pollutants can fall upon and quickly and may develop into a major repair expense.
Page 251: Gm Vehicle Care/Appearance Materials
yellowblue GM Vehicle Care/Appearance Materials PART NUMBER SIZE DESCRIPTION USAGE 994954 23 in. x 25 in. Polishing Cloth – Wax Treated Exterior polishing cloth 1050172 16 oz. (0.473 L) Tar and Road Oil Remover Removes tar, road oil and asphalt 1050173 16 oz.
Page 252: Vehicle Identification Number (Vin)
yellowblue Vehicle Identification Number (VIN) Service Parts Identification Label You’ll find this label in a location determined by the body manufacturer. It’s very helpful if you ever need to order parts. On this label is: your VIN, the model designation, paint information and a list of all production options and This is the legal identifier for your vehicle.
Page 253: Electrical System
yellowblue Electrical System Windshield Wipers Overload Protection The windshield wiper motor is protected by a circuit Add-On Electrical Equipment breaker inside the motor and a circuit breaker in the fuse block. If the motor overheats, the wipers will stop until the motor cools.
Page 254: Fuses And Circuit Breakers
yellowblue Fuses and Circuit Breakers Instrument Panel Circuit Breaker and Relay Blocks The wiring circuits in your vehicle are protected from short circuits by a combination of fuses, circuit breakers, maxi fuses and fusible links. This greatly reduces the chance of a fire caused by an electrical problem. There may be a fuse taped to the wiring harness inside the battery box and one near the generator also taped to the wiring harness.
Page 255 yellowblue If you ever have a problem on the road and don’t have a Number Circuits Protected spare circuit breaker, you can borrow one of the correct Engine ECU (TICS) value. Just pick some feature of your vehicle that you Glow Relay, ESC, EVRV, Gov.
Page 256 yellowblue Maxi Fuse Block Number Circuits Protected Checker Connector (TICS) When a circuit goes out, first check the instrument panel circuit breaker block. If no circuit breakers are out there, Trailer Turn (LH) Lamp, ID Lamp, the problem could be in the maxi fuse block.
Page 257 yellowblue Power is fed through these fuses to devices such as the Name Circuits/Circuit Breakers headlamp switch, ignition switch feed circuits and the Protected auxiliary brake pump (hydraulic brake vehicles). IGN SW1 Ignition Switch, Washer/Wiper, Be sure to replace maxi fuses with maxi fuses of the Crank, Radio...
Page 258: Replacement Bulbs
yellowblue Replacement Bulbs Engine Identification and Data Engine RPO LP4/L21 It is recommended that you use an AC type bulb whenever you need to replace one. Engine Type 6.0L V8 Before you replace any bulbs, be sure that all lamps are Fuel System HEUI SPFI...
Page 259: Crankcase Capacity
yellowblue Crankcase Capacity Transmission Fluid Capacity Capacities (volumes) shown are for normal refill. Add Capacities (volumes) shown are approximate. For oil as indicated when the oil filter element is changed. manual transmissions, the correct oil level is to the Capacities given are approximate keep level within bottom of the fluid fill plug opening.
Page 260: Air Conditioning Refrigerants
yellowblue Rear Axle Lubricant Capacity Air Conditioning Refrigerants Single Speed Axle Lubricant, Quarts (Liters) Not all air conditioning refrigerants are the same. 15040S ......10.7 (10.1) If the air conditioning system in your vehicle needs 19060S...
Page 261 yellowblue Service Replacement Part and Filter Recommendations Engine 7.2L 7.4L LP4/L21 Spark Plug — AC Type R43TS —Gap — 0.060 (1.52 mm) —Torque — 22.0 lb. ft. (30.0 N·m) Oil Filter 2P4004 AC Type PF PCV Valve — AC Type CV 774C Air Cleaner* Donaldson P134353...
Page 262 yellowblue NOTES 6-76...
Page 263: Section 7 Scheduled Maintenance Services
yellowblue Section 7 Scheduled Maintenance Services 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 264: Your Vehicle And The Environment
yellowblue 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 265: How This Section Is Organized
yellowblue How This Section is Organized If you are skilled enough to do some work on your vehicle, you will probably want to get the service This maintenance schedule is divided into five parts: information. See “Service and Owner Publications” in the Index.
Page 266: Using Your Maintenance Schedule
yellowblue 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 267: Scheduled Maintenance
yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) See the DURAMAX DIESEL Maintenance Schedule 1,000 Miles (1 600 km) that follows this schedule. Wheel stud nut service. (45)(46) The services shown in this schedule up to 100,000 miles 3,000 Miles (5 000 km) (166 000 km) should be performed after 100,000 miles Engine oil and filter service.
Page 268 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 6,000 Miles (10 000 km) (Continued) Chassis lubrication service (or every 6 months, whichever occurs first). (12) Lubricate door hinge pins and rollers with engine oil. Clean air conditioner filter (or every month, Wheels and tires service. (15) whichever occurs first).
Page 269 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 15,000 Miles (25 000 km) Clean air conditioner filter (or every month, whichever occurs first). See “Air Conditioner Filter” Engine oil and filter service. (3)(9) in the Index. Check fluid levels (or every 3 months, whichever Inspect door hinge pins and bushings and replace as occurs first).
Page 270 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 21,000 Miles (35 000 km) Wheels and tires service. (15) Hydraulic brake service (or every 6 months, Engine oil and filter service. (3)(9) whichever occurs first). (7) Check fluid levels (or every 3 months, whichever Hydraulic parking brake service (or every 6 months, occurs first).
Page 271 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) Check air brake relay valve operation and check for Clean air conditioner filter (or every month, leaks (or every month, or every 300 hours, whichever occurs first). See “Air Conditioner Filter” whichever occurs first). in the Index.
Page 272 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 30,000 Miles (50 000 km) (Continued) Inspect door hinge pins and bushings and replace as necessary. Lubricate door hinge pins and rollers with Clutch pedal free travel service. (10) engine oil. Air brake automatic slack adjuster service (or every Replace air conditioning filter dryer (or every 500 hours, whichever occurs first).
Page 273 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) Check air brake relay valve operation and check for Lubricate door hinge pins and rollers with engine oil. leaks (or every month, or every 300 hours, Wheels and tires service. (15) whichever occurs first). Hydraulic brake service (or every 6 months, Clean air brake application valve (or every 3 months, whichever occurs first).
Page 274 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 45,000 Miles (75 000 km) (Continued) Engine drive belts service (or every 12 months, whichever occurs first). (18) Air brake service (or every 6 months, whichever Clutch pedal free travel service. (10) occurs first). (39) Throttle linkage service.
Page 275 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 51,000 Miles (85 000 km) Replace air conditioning filter dryer (or every 18 months, whichever occurs first, and whenever Engine oil and filter service. (3)(9) refrigerant charge is lost for any reason). Check fluid levels (or every 3 months, whichever Wheels and tires service.
Page 276 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 60,000 Miles (100 000 km) Lubricate door hinge pins and rollers with engine oil. Wheels and tires service. (15) Engine oil and filter service. (3)(9) Hydraulic brake service (or every 6 months, Check fluid levels (or every 3 months, whichever whichever occurs first).
Page 277 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 63,000 Miles (105 000 km) 69,000 Miles (115 000 km) Engine oil and filter service. (3)(9) Engine oil and filter service. (3)(9) Check fluid levels (or every 3 months, whichever Check fluid levels (or every 3 months, whichever occurs first).
Page 278 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 72,000 Miles (120 000 km) (Continued) Air intake system service (or every 24 months, whichever occurs first). (4)(5)(24) Replace air conditioning filter dryer (or every Thermostatically controlled air cleaner service (or 18 months, whichever occurs first, and whenever every 24 months, whichever occurs first).
Page 279 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) Trailer brake hand control valve service (or every Chassis lubrication service (or every 6 months, 3 months, or 900 hours, whichever occurs first). (42) whichever occurs first). (12) Clean air conditioner filter (or every month, 75,000 Miles (125 000 km) whichever occurs first).
Page 280 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 84,000 Miles (140 000 km) Shields and undercab insulation service. (4)(5)(21) Check air brake relay valve operation and check for Engine oil and filter service. (3)(9) leaks (or every month, or every 300 hours, Check fluid levels (or every 3 months, whichever whichever occurs first).
Page 281 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) Replace fuel filter(s) (or every 12 months, whichever Wheels and tires service. (15) occurs first). (3) Hydraulic brake service (or every 6 months, Air cleaner filter replacement service (or every whichever occurs first). (7) 24 months, whichever occurs first).
Page 282 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 96,000 Miles (160 000 km) Clutch pedal free travel service. (10) Throttle linkage service. (19) Engine oil and filter service. (3)(9) Thermostatically controlled engine cooling fan Check fluid levels (or every 3 months, whichever service.
Page 283 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) 99,000 Miles (165 000 km) 150,000 Miles (240 000 km) Engine oil and filter service. (3)(9) Cooling system service (or every 60 months since last service, whichever occurs first). (3)(35) Check fluid levels (or every 3 months, whichever occurs first).
Page 284 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) Footnotes pump (if equipped). A low fluid level in the brake master cylinder can indicate worn brake linings and = The U.S. Environmental Protection Agency or the should be checked accordingly. California Air Resources Board has determined that the (7) = Inspect brake lines and hoses for proper hook failure to perform this maintenance item will not nullify binding, leaks, cracks, chafing, etc.
Page 285 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) The system won’t detect dust in the oil. So if you drive latches and cab hinges, parking brake lever pivot, clevis in a dusty area, be sure to change your oil and filter pins and linkage, disc brake caliper rails, clutch linkage every 3,000 miles (5 000 km) or sooner if the Change and release bearing (if equipped), propeller shaft slip Oil Light comes on.
Page 286 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) Check steering gear for leakage around pitman (17) = Check complete exhaust system and cab areas shaft and housing. If leakage is evident (lubricant near the exhaust system for broken, damaged, missing or oozing out, not just oily film), leak should be position parts.
Page 287 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) (23) = Wheel bearing service: (25) = Check thermostatically controlled air cleaner installation to make certain that all ducts are Grease type Clean, inspect and lubricate with the connected and correctly installed. Also, check valve for proper wheel bearing grease at designated intervals proper operation.
Page 288 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) (31) = Check EGR system as described in the service (37) = Rear axle service: Change the lubricant. See manual. See “Service and Owner Publications” in “Recommended Fluids and Lubricants” in the Index. the Index. (38) = Front axle service: Re pack upper kingpin (32) = Inspect Electronic Vacuum Regulator Valve...
Page 289 yellowblue Scheduled Maintenance (Except DURAMAX DIESEL) Inspect air parking brake chamber for leaks and Remove, disassemble and clean the application valve; damage. Inspect lines and hoses for leaks, cracks, replace parts showing wear. Remove, disassemble, clean chafing, etc. Also check all attachments for and inspect the spring brake control valve;...
Page 290 yellowblue Scheduled Maintenance (DURAMAX DIESEL) The services shown in this schedule up to 100,000 miles Lubricate clutch shift block (or every month, (166 000 km) should be performed after 100,000 miles whichever occurs first). (166 000 km) at the same intervals. The services shown Rear axle air shift motor service.
Page 291 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Wheels and tires service. (15) 13,000 Miles (20 800 km) Hydraulic brake service (or every 6 months, Change engine oil and filters (or every 3 months, whichever occurs first). (7) whichever occurs first). (3)(9) Hydraulic parking brake service (or every 6 months, Check fluid levels (or every 3 months, whichever whichever occurs first).
Page 292 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 13,000 Miles (20 800 km) (Continued) 16,250 Miles (26 000 km) Exhaust system service (or every month, whichever Check fluid levels (or every 3 months, whichever occurs first). (3)(4)(17) occurs first). (1)(2)(6) Air brake service (or every 6 months, whichever Clean air conditioner filter (or every month, occurs first).
Page 293 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Lubricate steering column shaft (or every 3 months, 22,750 Miles (36 400 km) whichever occurs first). Check fluid levels (or every 3 months, whichever Inspect door hinge pins and bushings and replace as occurs first). (1)(2)(6) necessary.
Page 294 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 26,000 Miles (41 600 km) (Continued) Hydraulic brake service (or every 6 months, whichever occurs first). (7) Lubricate steering column shaft (or every 3 months, Hydraulic parking brake service (or every 6 months, whichever occurs first). whichever occurs first).
Page 295 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Air brake chamber service (or every 2 months, 32,500 Miles (52 000 km) whichever occurs first). (41) Change engine oil and filters (or every 3 months, Trailer brake hand control valve service (or every whichever occurs first). (3)(9) 3 months, or 900 hours, whichever occurs first).
Page 296 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 32,500 Miles (52 000 km) (Continued) Clean air conditioner filter (or every month, whichever occurs first). See “Air Conditioner Filter” Clutch pedal free travel service. (10) in the Index. Lubricate clutch shift block (or every month, Lubricate water pump (or every 3 months, whichever whichever occurs first).
Page 297 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Hydraulic brake service (or every 6 months, 42,250 Miles (67 600 km) whichever occurs first). (7) Check fluid levels (or every 3 months, whichever Hydraulic brake caliper service (or every 6 months, occurs first). (1)(2)(6) whichever occurs first).
Page 298 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 45,500 Miles (72 800 km) (Continued) 52,000 Miles (83 200 km) Lubricate steering column shaft (or every 3 months, Change engine oil and filters (or every 3 months, whichever occurs first). whichever occurs first). (3)(9) Lubricate door hinge pins and rollers with engine oil.
Page 299 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Air brake service (or every 6 months, whichever Throttle linkage service. (19) occurs first). (39) Thermostatically controlled engine cooling fan Check curb idle speed (or every 12 months, service. (4)(20) whichever occurs first). (29) Shields and undercab insulation service (or every Injector service (or every 12 months, whichever month, whichever occurs first).
Page 300 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 52,000 Miles (83 200 km) (Continued) 58,500 Miles (93 600 km) Air brake chamber service (or every 2 months, Change engine oil and filters (or every 3 months, whichever occurs first). (41) whichever occurs first). (3)(9) Trailer brake hand control valve service (or every Check fluid levels (or every 3 months, whichever 3 months, or 900 hours, whichever occurs first).
Page 301 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Hydraulic brake service (or every 6 months, 65,000 Miles (104 000 km) whichever occurs first). (7) Change engine oil and filters (or every 3 months, Hydraulic brake caliper service (or every 6 months, whichever occurs first). (3)(9) whichever occurs first).
Page 302 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 65,000 Miles (104 000 km) (Continued) Check air brake relay valve operation and check for leaks (or every month, or every 300 hours, Replace fuel filter (or every 6 months, whichever whichever occurs first). occurs first). Exhaust system service (or every month, whichever 68,250 Miles (109 200 km) occurs first).
Page 303 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Lubricate water pump (or every 3 months, whichever Lubricate clutch shift block (or every month, occurs first). whichever occurs first). Lubricate steering column shaft (or every 3 months, 78,000 Miles (124 800 km) whichever occurs first). Change engine oil and filters (or every 3 months, Lubricate door hinge pins and rollers with engine oil.
Page 304 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 78,000 Miles (124 800 km) (Continued) Thermostatically controlled engine cooling fan service. (4)(20) Spring axle U bolts and shackle bolts service. (16) Shields and undercab insulation service (or every Exhaust system service (or every month, whichever month, whichever occurs first).
Page 305 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Trailer brake hand control valve service (or every Chassis lubrication service (or every 6 months, 3 months, or 900 hours, whichever occurs first). (42) whichever occurs first). (12) Air brake automatic slack adjuster service (or every Clean air conditioner filter (or every month, 500 hours, whichever occurs first).
Page 306 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 87,750 Miles (140 400 km) Lubricate steering column shaft (or every 3 months, whichever occurs first). Wheel bearings service Eaton Axle (oil filled) (or Lubricate door hinge pins and rollers with engine oil. every 24 months, whichever occurs first). (23) Steering system service.
Page 307 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Thermostatically controlled engine cooling fan Chassis lubrication service (or every 6 months, service. (4)(20) whichever occurs first). (12) Shields and undercab insulation service (or every Clean air conditioner filter (or every month, month, whichever occurs first). (4)(5)(21) whichever occurs first).
Page 308 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 97,500 Miles (156 000 km) (Continued) Front axle service (or every 36 months, whichever occurs first). (38) Hydraulic brake caliper service (or every 6 months, Rear axle service Eaton Axle (or every 12 months, whichever occurs first). (22) whichever occurs first).
Page 309 yellowblue Scheduled Maintenance (DURAMAX DIESEL) 250,000 Miles (400 000 km) Footnotes Wheel bearings service Eaton Axle (oil filled) (1) = If your vehicle has an Allison automatic (or every 36 months, whichever occurs first). (23) transmission, your GM Owner’s Manual is supplemented Rear axle service Eaton Axle (or every 36 months, by an Allison Transmission Operator’s Manual.
Page 310 yellowblue Scheduled Maintenance (DURAMAX DIESEL) (8) = Inspect hydraulic parking brake drum and linings (12) = Chassis Lubrication Service: Lubricate all grease for wear or cracks and check linkage and adjustment. fittings in front suspension, front axle and steering Check spring brake actuator and pump for leaks. linkage.
Page 311 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Inspect power steering hoses, tubes and fittings for (17) = Check complete exhaust system and cab areas leaks. Hoses and lines must not be twisted, kinked or near the exhaust system for broken, damaged, missing or tightly bent.
Page 312 yellowblue Scheduled Maintenance (DURAMAX DIESEL) (21) = Check shields and undercab insulation for (25) = Check injection timing; incorrect injection timing damage or looseness. Adjust or replace as needed. could result in increased exhaust emission or smoke emission or reduced engine output. With an injector (22) = Lubricate caliper housing, caliper support spring cleaning tool, clean the outside of the injector end.
Page 313 yellowblue Scheduled Maintenance (DURAMAX DIESEL) Check fuel cap gasket for even filler neck imprint. Test air lines for leaks; tighten as needed. Replace Replace parts as needed. compressor filter. Inspect air parking brake chamber for leaks and (35) = Drain, flush and refill cooling system. See damage.
Page 314 yellowblue Scheduled Maintenance (DURAMAX DIESEL) (44) = Air brake service: Remove, disassemble, clean (46) = For Hub Piloted Wheels Only: Tighten the wheel and inspect the safety valve, standard brake chamber, stud nuts to the specified torque values at 1,000 miles quick release valve, quick release/double check valve (1 600 km).
Page 315: At Each Fuel Fill
yellowblue Part B: Owner Checks and Services Engine Oil Level Check Check the engine oil level and add the proper oil if Listed in this part are owner checks and services which necessary. See “Engine Oil” in the Index for should be performed at the intervals specified to help further details.
Page 316: At Least Twice A Year
yellowblue At Least Twice a Year Body Lubrication Service Lubricate all exposed surfaces such as door checks, door Restraint System Check lock bolts, lock strike plates, door hinge bushings and Make sure the safety belt reminder light and all your dovetail bumper wedges.
Page 317 yellowblue Starter Switch Check Automatic Transmission Shift Indicator Check Check that the indicator points to the gear chosen. CAUTION: Steering Check Be alert for any changes in steering action, abnormal When you are doing this check, the vehicle could front tire wear or steering wheel position. An inspection move suddenly.
Page 318 yellowblue Engine Cooling System Service Mirrors and Sun Visors Check Inspect the hoses and have them replaced if they are Check that friction joints hold mirrors and sun visors cracked, swollen or deteriorated. Inspect all pipes, in place. fittings and clamps; replace as needed. Clean the outside Seat Adjuster Check of the radiator and air conditioning condenser.
Page 319 yellowblue Door Latches Check Engine Cover Check Check that doors close, latch and lock tightly. Check for Check that the cab’s engine cover and seal (if equipped) broken, damaged or missing parts that might prevent are not torn or damaged. Be sure that the cover is bolted tight latching.
Page 320 yellowblue Part C: Recommended Fluids USAGE FLUID/LUBRICANT and Lubricants Engine Coolant See the Caterpillar Operation & (Caterpillar Maintenance Manual for Engine NOTE: Fluids and lubricants identified below by name, Diesel Engine) Coolant recommendations. part number or specification may be obtained from your dealer.
Page 321 yellowblue USAGE FLUID/LUBRICANT USAGE FLUID/LUBRICANT Brake Caliper Aeroshell #5 Grease (GM Part No. Chassis Chassis Lubricant (GM Part No. Housing, Caliper 12377969 or equivalent). Lubrication 12377985 or equivalent) or Support Spring lubricant meeting requirements and Caliper of NLGI # 2, Category LB Support Key or GC Air Brake...
Page 322 yellowblue USAGE FLUID/LUBRICANT USAGE FLUID/LUBRICANT Rear Axle Shift Refrigerant Oil (GM Part Weatherstrip Dielectric Silicone Grease (GM Motor Lubricant No. 5416939). Conditioning Part No. 12345579 or equivalent). Propshafts and Wheel Bearing Lubricant meeting Weatherstrip Synthetic Grease with Teflon, Splines requirements of NLGI # 2, Squeaks Superlube (GM Part No.
Page 323: Maintenance Record
yellowblue Part D: Maintenance Record After the scheduled services are performed, enter the added on the following record pages. Also, you should date, odometer reading and services performed on the retain all maintenance receipts. Your owner information maintenance record charts provided here. Any additional portfolio is a convenient place to store them.
Page 324 yellowblue Maintenance Record ODOMETER DATE SERVICED BY MAINTENANCE PERFORMED READING 7-62...
Page 325: 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...
Page 326: Customer Satisfaction Procedure
Customer Satisfaction Procedure Your satisfaction and goodwill are important to your dealer and to GMC. Normally, any concerns with the sales transaction or the operation of your vehicle will be resolved by your dealer’s sales or service departments. Sometimes, however, despite the best intentions of all concerned, misunderstandings can occur.
Page 327: Customer Assistance For Text Telephone (Tty) Users
GMC encourages customers to call the toll-free number concern will likely be resolved at a dealer’s facility. That for assistance. If a U.S. customer wishes to write to GMC, is why we suggest you follow Step One first if you have the letter should be addressed to GMC’s Customer...
Page 328: All Overseas Locations
yellowblue Canada Caribbean Numbers General Motors of Canada Limited 1-800-496-9992 (English) Puerto Rico Customer Communication Centre, 163-005 1-800-496-9993 (Spanish) Puerto Rico 1908 Colonel Sam Drive 1-800-751-4135 (English) Dominican Republic Oshawa, Ontario L1H 8P7 1-800-751-4136 (Spanish) Dominican Republic 1-800-496-9994 U.S. Virgin Islands 1-800-263-3777 (English) 1-800-389-0009 Bahamas 1-800-263-7854 (French)
Page 329: Roadside Assistance
Roadside Assistance is available 24 hours a day, 7 days a week, 365 days a year, including weekends and holidays. Should you have any questions about Roadside Assistance, call the GMC Roadside Assistance Center or contact your dealer. Warranty Information GM Medium Duty Truck’s Roadside Assistance...
Page 330: Reporting Safety Defects To The United States Government
yellowblue REPORTING SAFETY DEFECTS REPORTING SAFETY DEFECTS TO TO THE UNITED STATES THE CANADIAN GOVERNMENT GOVERNMENT If you live in Canada, and you believe that your vehicle has a safety defect, you should immediately notify If you believe that your vehicle has a defect which could Transport Canada, in addition to notifying General cause a crash or could cause injury or death, you should Motors of Canada Limited.
Page 331: Reporting Safety Defects To General Motors
Please call us at 1 8782 past model General Motors vehicles. 8782), or write: The toll-free telephone number for ordering information Pontiac-GMC Customer Assistance Center in Canada is 1-800-668-5539. P.O. Box 436008 Pontiac, MI 48343 6008 3777 (English)
Page 332 1999 GMC SERVICE PUBLICATIONS ORDERING INFORMATION The following publications covering the operation and servicing of your vehicle can be purchased by filling out the Service Publication Order Form in this book and mailing it in with your check, money order, or credit card information to Helm, Incorporated (address below.)
Page 333 DAYTIME TELEPHONE NO. CUSTOMER SIGNATURE AREA CODE GM-GMC-ORD99 *(Prices are subject to change without notice and without incurring Note to Canadian Customers: All listed prices are quoted in U.S. funds. Canadian residents obligation. Allow ample time for delivery.) are to make checks payable in U.S.
Page 334 yellowblue NOTES 8-10...
Page 335: Section 9 Index
yellowblue Section 9 Index Appearance Care Materials Chart ....Brake System Warning Lights ....Apply Park Brake Warning Light .
Page 336 yellowblue Brake (Continued) Check Gages Indicator Light ..... . Fluid ........Checking Your Restraint Systems .
Page 337 yellowblue Cooling System Door Capacity ........Locks .
Page 338 yellowblue Engine (Continued) Stopping the Diesel ......Coolant Temperature Gage ..... Stopping the Gasoline .
Page 339 yellowblue Flashers, Hazard Warning ......Gasoline Engine Oil ......Flat Tire, Changing .
Page 340 yellowblue gnition Positions ....... Brake System Warning ......Inflation, Tire .
Page 341 yellowblue Maintenance, Underbody ......aint Spotting, Chemical ......Malfunction Indicator Lamp .
Page 342 yellowblue Refrigerants, Air Conditioning ....Safety Defects, Reporting ..... 6, 8 Replacement, Wheels .
Page 343 yellowblue Steering ........Inflation .
Page 344 yellowblue nderbody Inspection ......Wheel Underbody Maintenance ......Alignment .

GMC T-Series 1999 Owner's Manual

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