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Chevrolet C6H042, Owner'S Manual

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Chevrolet C6H042 Owner'S Manual Download Page 240

6-37

Clutch Pedal Free Travel

If you have a manual transmission, your clutch will 
need adjustment when pedal free travel gets down to
about 1 1/4 inch (32 mm), as measured at the clutch
pedal pad. You should have 1 1/2 to 2 inches 
(38 to 51 mm) of clutch pedal free travel. Your
Maintenance Schedule has more on this.

If your clutch ever needs service, be sure to use only
genuine GM clutch replacement parts.

Chassis Lubrication

Your Maintenance Schedule provides all of the required
chassis lubrication intervals and identifies proper
lubricants to use. Be sure to see your Maintenance
Schedule before performing any chassis lubrication
service. To determine location of chassis lubrication
items, use the following charts.

Summary of Contents for C6H042

Page 1: ......

Page 2: ...i 2002 Chevrolet C Series Owner s Manual Litho in U S A ECopyright General Motors Corporation 06 11 01 Part Number C2202 A First Edition All Rights Reserved...

Page 3: ...Canada Limited for GM Medium Duty Truck Division whenever it appears in this manual Please keep this manual in your vehicle so it will be there if you ever need it when you re on the road If you sell...

Page 4: ...d a number of safety cautions in this book We use a box and the word CAUTION to tell you about things that could hurt you if you were to ignore the warning CAUTION These mean there is something that c...

Page 5: ...ings in different colors or in different words You ll also see warning labels on your vehicle They use the same words CAUTION or NOTICE Vehicle Symbols Your vehicle may be equipped with components and...

Page 6: ...v These are some examples of vehicle symbols you may find on your vehicle...

Page 7: ...Series models delivered from the factory are finished in a variety of ways by a number of companies you ll probably find other manuals in your finished vehicle These manuals are put there by the compa...

Page 8: ...Safety Belts They re for Everyone 1 11 Here are Questions Many People Ask About Safety Belts and the Answers 1 12 How to Wear Safety Belts Properly 1 12 Driver Position 1 21 Safety Belt Use During Pre...

Page 9: ...use you or make you push a pedal when you don t want to Adjust the driver s seat only when the vehicle is not moving Bucket and Bench Seats If your vehicle has a bucket or bench seat you can adjust it...

Page 10: ...e full width bench seat seatback folds forward to let you reach the rear of the cab Bucket seats have outboard mounted levers to tilt the seatbacks forward or rearward Your seatback will move back and...

Page 11: ...rly CAUTION If the seatback isn t locked it could move forward in a sudden stop or crash That could cause injury to the person sitting there Always press rearward on the seatback to be sure it is lock...

Page 12: ...nob on the front outboard side of the seat Push the knob to inflate Pull the knob to deflate To adjust the height of the cushion lift the cushion height adjustment handle up and forward You can choose...

Page 13: ...ger s side of the vehicle The seat will lock in at 1 2 inch 1 5 cm increments The lever is located underneath the seat in the front Chugger Snubber Lock Out Feature If Equipped If your vehicle has thi...

Page 14: ...same crash you might not be if you are buckled up Always fasten your safety belt and check that your passengers belts are fastened properly too CAUTION It is extremely dangerous to ride in a cargo are...

Page 15: ...ashes can be so serious that even buckled up a person wouldn t survive But most crashes are in between In many of them people who buckle up can survive and sometimes walk away Without belts they could...

Page 16: ...1 9 If the vehicle hits something it stops right then But nothing stops the people They keep moving Then something will stop them It could be the windshield...

Page 17: ...sengers were to give that big vehicle a chance to deal with the force of the impact instead of you With belts you slow down as the vehicle does You get more time to stop You stop over more distance an...

Page 18: ...ey work with safety belts not instead of them Every air bag system ever offered for sale has required the use of safety belts Even if you re in a vehicle that has air bags you still have to buckle up...

Page 19: ...vehicle see the part of this manual called Children Follow those rules for everyone s protection First you ll want to know which restraint systems your vehicle has We ll start with the driver position...

Page 20: ...h plate to make sure it is secure If the belt is pulled out all the way so that it locks press down on the button on the retractor cover to make it retract If the belt isn t long enough see Safety Bel...

Page 21: ...1 14 If the shoulder belt is too tight D Pull out the belt at least 5 inches 130 mm D Let it go back all the way...

Page 22: ...make it tight again The lap part of the belt should be worn low and snug on the hips just touching the thighs In a crash this applies force to the strong pelvic bones And you d be less likely to slid...

Page 23: ...give nearly as much protection this way 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 s...

Page 24: ...ou can be seriously injured if your belt is buckled in the wrong place like this In a crash the belt would go up over your abdomen The belt forces would be there not at the pelvic bones This could cau...

Page 25: ...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...

Page 26: ...sted across the body 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...

Page 27: ...ack out of the way For a suspension type seat if the belt is pulled out all the way so that it locks press down on the button on the retractor cover to make it retract Before you close the door be sur...

Page 28: ...worn as low as possible below the rounding throughout the pregnancy The best way to protect the fetus is to protect the mother When a safety belt is worn properly it s more likely that the fetus won t...

Page 29: ...has a full bench seat or a two passenger bench seat someone can sit in the center position When you sit in a center seating position you have a lap safety belt which has no retractor To make the belt...

Page 30: ...one in a vehicle needs protection This includes infants and all other children Neither the distance traveled nor the age and size of the traveler changes the need for everyone to use safety restraints...

Page 31: ...uch until a crash During a crash a baby will become so heavy it is not possible to hold it CAUTION Continued CAUTION Continued For example in a crash at only 25 mph 40 km h a 12 lb 5 5 kg baby will su...

Page 32: ...raint will have a label saying that it meets federal motor vehicle safety standards The restraint manufacturer s instructions that come with the restraint state the weight and height limitations for a...

Page 33: ...d cause serious or fatal injuries Young children always should be secured in appropriate child restraints We know securing a child can present real problems in a medium duty vehicle like yours The onl...

Page 34: ...restrain or position a child on a continuous flat surface Make sure that the infant s head rests toward the center of the vehicle A rear facing infant seat B provides restraint with the seating surfac...

Page 35: ...urfaces such as T shaped or shelf like shields A booster seat F G is a child restraint designed to improve the fit of the vehicle s safety belt system Some booster seats have a shoulder belt positione...

Page 36: ...t type shield has straps that are attached to a wide shelf like shield that swings up or to the side When choosing a child restraint be sure the child restraint is designed to be used in a vehicle If...

Page 37: ...estraints are designed for use with or without the top strap being anchored Others require the top strap always to be anchored Be sure to read and follow the instructions for your child restraint If y...

Page 38: ...estraint when and as the instructions say But don t use this position if the child restraint interferes with shifting gears See the earlier part about the top strap if the child restraint has one 1 Ma...

Page 39: ...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 6 Push and pull the c...

Page 40: ...le an older child should wear a lap shoulder belt and get the additional restraint a shoulder belt can provide The shoulder belt should not cross the face or neck The lap belt should fit snugly below...

Page 41: ...r belt but the child is so small that the shoulder belt is very close to the child s face or neck A Move the child toward the center of the vehicle but be sure that the shoulder belt still is on the c...

Page 42: ...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 That could cause serious or fatal injuries Wherever the child sits the...

Page 43: ...tch plates retractors and anchorages are working properly Look for any other loose or damaged safety belt system parts If you see anything that might keep a safety belt system from doing its job have...

Page 44: ...l Engine Exhaust Brake 2 20 Two Speed Rear Axle Electric Shift Control If Equipped 2 23 Automatic Transmission Operation 2 24 Manual Transmission Operation 2 26 Parking 2 33 Parking Over Things That B...

Page 45: ...cle with the windows closed is dangerous A child can be overcome by the extreme heat and can suffer permanent injuries or even death from heat stroke Never leave a child alone in a vehicle especially...

Page 46: ...e power windows the controls are located on each door The driver s door has a switch for the passenger s window as well Your power windows will not move unless the ignition switch is turned to ON Push...

Page 47: ...le with the ignition key is dangerous for many reasons A child or others could be badly injured or even killed They could operate the power windows or other controls or even make the vehicle move Don...

Page 48: ...m to the first owner Each plug has a code on it that tells your dealer or a qualified locksmith how to make extra keys Keep the plugs in a safe place If you lose your keys you ll be able to have new o...

Page 49: ...D Young children who get into unlocked vehicles may be unable to get out A child can be overcome by extreme heat and can suffer permanent injuries or even death from heat stroke Always lock your vehi...

Page 50: ...the door 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...

Page 51: ...D Avoid making hard stops for the first 200 miles 322 km or so During this time your new brake linings aren t yet broken in Hard stops with new linings can mean premature wear and earlier replacement...

Page 52: ...l damage to the starter If the starter motor overheats and shuts off due to over cranking the motor must cool down before the switch will reset and allow you to operate the starter It can take up to s...

Page 53: ...sengage if after two seconds the starter pinion gear does not engage the flywheel or there is no engine rpm signal from the engine speed sensor Starting Your Engine 1 Without pushing the accelerator p...

Page 54: ...Automatic Transmission If you have to restart the engine while the vehicle is moving you ll first have to shift the automatic transmission to NEUTRAL N This safety feature prevents starting the engine...

Page 55: ...ual that tells how to do it without damaging your vehicle See Towing Your Vehicle in the Index Restarting the Diesel Engine While Moving Automatic Transmission If you have to restart the engine while...

Page 56: ...starting fluid or you could damage your engine If you have the GM system use only GM approved starting fluid that has been tested to establish compatibility with the air inlet heater system Diesel Eng...

Page 57: ...fic you can restart the engine and get another 25 seconds of operation Do this only if you have to since there is a problem that can harm the engine if it isn t fixed Engine automatic shutdown for gas...

Page 58: ...on if equipped is in NEUTRAL N The manual fast idle feature is activated by pressing the switch on the instrument panel When the switch is pressed again or any of the previous conditions are not met m...

Page 59: ...se within 15 seconds of starting stop the engine and find the cause D If the engine coolant temperature gage needle goes into the hot area on the gage stop the engine and find the cause of the overhea...

Page 60: ...Engine idle speed should be increased to 1200 rpm whenever extended idle is required Once started the engine should be placed under load to allow the engine coolant temperature to reach 150_F 66_C bef...

Page 61: ...olant heater plugged in The answer depends on the outside temperature From 32_F to 10_F 0_C to 23_C keep the coolant heater plugged in at least two hours Below 10_F 23_C keep the coolant heater plugge...

Page 62: ...lerator and clutch pedals must be released in order for the exhaust brake to engage Do not use the exhaust brake when running the engine at idle during warm up or other extended periods Prolonged use...

Page 63: ...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 Apply the parking brake shift to PARK P or NEUTRAL N and shut off the engine...

Page 64: ...high range disengage the clutch pause engage the clutch and then press down on the accelerator When you shift the axle down from high to low you don t have to clutch Just move the switch down to low r...

Page 65: ...a low profile option for operations which require extra cubic capacity and a reduced deck height With this air suspension system the ride height is set during vehicle assembly so that the vehicle has...

Page 66: ...smissions can be started in PARK P if equipped or in NEUTRAL N When you shift out of NEUTRAL N you may have to hold in a push button on the shift lever or lift up on a release handle as you shift See...

Page 67: ...n for an engine speed drop of about 100 rpm At this point the clutch is engaging so you should increase the engine speed and fully engage the clutch It s important not to increase the engine speed soo...

Page 68: ...edures when shifting D Never move the range shift knob with the transmission shift lever in neutral while the vehicle is moving D Never make a range shift while moving in REVERSE R Double Clutching Yo...

Page 69: ...R gear NOTICE After engaging FIRST 1 or REVERSE R gear do not use the clutch brake for upshifting and downshifting To do so will shorten the service life of the clutch brake and gear selection shift e...

Page 70: ...n which has a shift lever This lever will have PARK P on the shift indicator This position locks your rear wheels But even with the transmission in PARK P be sure the parking brake is set firmly Props...

Page 71: ...he lever seem harder to pull up Turning the knob counterclockwise makes the parking brake apply less firmly Adjust the parking brake only when the lever is down released If your parking brake doesn t...

Page 72: ...o the right of the steering column To apply the parking brake pull the knob toward you Then shift the transmission to neutral or PARK P Push the knob in to release the parking brake The ignition must...

Page 73: ...ike someone or something When both of these knobs are pushed in either hold the regular brake pedal down or if you have it pull out the blue TRACTOR PARKING knob to keep your rig from moving If your v...

Page 74: ...oth the yellow SYSTEM PARK and the red TRAILER AIR SUPPLY knobs This will charge your trailer s air system If you have the blue TRACTOR PARKING knob pull it out to set the tractor brakes while the air...

Page 75: ...ht will come on If the air pressure drops to 40 to 45 psi 275 to 309 kPa the SYSTEM PARK knob will automatically pop out and apply the spring brakes If you ever have a complete loss of air so that you...

Page 76: ...ciousness and death You might have exhaust coming in if D Your exhaust system sounds strange or different D Your vehicle gets rusty underneath D Your vehicle was damaged in a collision D Your vehicle...

Page 77: ...g One place this can happen is a garage Exhaust with CO can come in easily NEVER park in a garage with the engine running Another closed in place can be a blizzard See Blizzard in the Index CAUTION It...

Page 78: ...s controlled by a cord that you ll find up above and to the left of the driver The harder you pull on the cord the louder the air horn will sound The air horn works only after your air system pressure...

Page 79: ...d the lever will return automatically An arrow on the instrument panel cluster will flash in the direction of the turn or lane change To signal a lane change just raise or lower the lever until the ar...

Page 80: ...o the center position An arrow on the instrument panel cluster will flash in the direction of the turn when the lever is in the up or down position This system replaces the turn signal feature on the...

Page 81: ...Windshield Wipers The windshield wipers are controlled by turning the band with the wiper symbol on it For a single wiping cycle turn the band to MIST Hold it there until the wipers start then let go...

Page 82: ...dshield Washer At the top of the multifunction lever there s a paddle with the word PUSH on it To spray washer fluid on the windshield push the paddle CAUTION In freezing weather don t use your washer...

Page 83: ...nsmission and you apply your brakes the cruise control will shut off If you have a manual transmission and you apply your brakes or push the clutch pedal the cruise control will shut off CAUTION D Cru...

Page 84: ...t 4 Take your foot off the accelerator pedal Resuming a Set Speed Once you re going about 30 mph 48 km h or more you can move the cruise control switch from ON to R A Resume Accelerate briefly The veh...

Page 85: ...ds the cruise control will automatically turn off The cruise control function will be made available again the next time the engine is started Reducing Speed While Using Cruise Control Press in the bu...

Page 86: ...ower gear to keep your speed down Of course applying the brake or clutch takes you out of cruise control Many drivers find this to be too much trouble and don t use cruise control on steep hills Endin...

Page 87: ...e way if you have to Use this control only when you re driving Don t use it for parking or to hold the rig on a hill CAUTION Using the trailer brake hand control for parking or for holding the vehicle...

Page 88: ...ifferentials so that power is transmitted equally to both rear axles NOTICE Activating the inter axle differential lock when the rear wheels are actually spinning freely as they might on ice or snow c...

Page 89: ...like one or even both wheels may start to slip you can use this control It locks your rear differential so that power is transmitted equally to both rear wheels Let up on the accelerator before you tu...

Page 90: ...e supply is closed off from the front scoop and an under hood air supply is opened This control is intended only for use in cold weather 32_ F 0_ C or below where snow and ice might plug the external...

Page 91: ...rking lamps together with the following D Marker Lamps if your vehicle has the marker and clearance lamps switch D Taillamps D License Plate Lamps D Instrument Panel Lights Headlamps Pressing this swi...

Page 92: ...ess in daylight when the following conditions are met D The ignition is on D the headlamp switch is off and D the parking brake is released When the DRL are on only your low beam headlamps will be on...

Page 93: ...el just above the radio If your vehicle doesn t have a radio the switch is located just above the storage area Use the switch to operate your clearance and marker lamps The marker lamps are illuminate...

Page 94: ...iver s door You can also turn the dome lamps on by turning the instrument panel brightness control all the way up until it clicks Mirrors Inside Rearview Mirror If Equipped Press the tab under the mir...

Page 95: ...hanging lanes Heated Outside Mirrors If Equipped If your vehicle has heated mirrors you ll find this switch on the upper right side of your instrument panel area just above the radio Use it to operate...

Page 96: ...te lighter in with your hand while it is heating If you do it won t be able to back away from the heating element when it s ready That can make it overheat damaging the lighter and heating element To...

Page 97: ...negative black outlets They have a 20 amp fuse that is common with the cigarette lighter Don t use the cigarette lighter when you re using a power jack because it may overload the circuit and blow th...

Page 98: ...le that will go to the trailer to supply electrical power to the trailer s lighting system When not in use it is stored in the trailer air hose storage bracket NOTICE Starting in 1998 the center pin a...

Page 99: ...2 56 The Instrument Panel Your Information System...

Page 100: ...ster E Warning Lights F Heated Mirror Switch If Equipped G Diesel Engine Exhaust Brake Switch H Marker Clearance Lamps Switch If Equipped I Audio System or Storage Area J Glove Box K Hourmeter If Equi...

Page 101: ...l 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 econom...

Page 102: ...e mileage total of the old odometer then it must be But if it can t then it s set at zero and a label must be put on the driver s door to show the old mileage reading when the new odometer was install...

Page 103: ...ing attention to your warning lights and gages could also save you or others from injury Warning lights come on when there may be or is a problem with one of your vehicle s functions As you will see i...

Page 104: ...their safety belts Safety Belt Reminder Tone Option When the key is turned to RUN or START a tone will sound for about eight seconds to remind people to fasten their safety belts Charging System Indic...

Page 105: ...the instrument panel cluster shows the charging system voltage Readings in either warning zone indicate a possible problem in the electrical system Readings in the low warning zone may occur when a l...

Page 106: ...ear to stay in so that you can drive the vehicle in that gear You may not be able to drive as fast or back up when this light is on NOTICE If the check transmission warning light comes on while you ar...

Page 107: ...Warning Light Your vehicle has either hydraulic or air brakes Each system has different warning lights Hydraulic Brake System Warning Lights Vehicles with hydraulic systems have two brake system warni...

Page 108: ...ted right away If one or both of these lights come on and stay on while you are driving pull off the road and stop carefully You may notice that the pedal is harder to push Or the pedal may go closer...

Page 109: ...ome on while you are driving you should drive only as far as the nearest point of safety and then stop the vehicle Here s a very important thing for you to know CAUTION If the LOW AIR warning light co...

Page 110: ...on as a check when the engine is first started and any time the system needs adjustment or there is a malfunction in the electric hydraulic parking brake system When the SERVICE PARK BRAKE light comes...

Page 111: ...ke system this light will come on when you start your engine and it may stay on for several seconds That s normal If the light stays on or comes on when you re driving your vehicle needs service If th...

Page 112: ...ely If an anti lock brake system equipped trailer is not connected this light is not functional Engine Coolant Temperature Gage Gasoline Engine Diesel Engine This gage shows the engine coolant tempera...

Page 113: ...n This light may also come on if your vehicle is equipped with the optional automatic engine shutdown system and engine shutdown has begun See Engine Automatic Shutdown in the Index Manual Fast Idle I...

Page 114: ...l for the light to cycle on and off as the heater cycles during engine warm up See Engine Starting in your CaterpillarR Operation Maintenance Manual for more information Service Transmission Filter In...

Page 115: ...gine may not run properly or may stall without warning If either of these things happen drive or tow your vehicle to your dealer for service This light should come on when the ignition is on but the e...

Page 116: ...l If you have a diesel engine the normal operating range should be between 35 and 70 psi 240 to 480 kPa A reading in the low pressure zone may be caused by a dangerously low oil level or other problem...

Page 117: ...Index Reduced Engine Power Warning Light If the CHECK ENGINE and REDUCED ENGINE POWER lights are on a noticeable reduction in the vehicle s performance may occur If the REDUCED ENGINE POWER light is o...

Page 118: ...system is in use Transmission Temperature Gage Option If you have an automatic transmission equipped with this gage it is located to the right of the dash mounted shift lever When your ignition is on...

Page 119: ...ine coolant temperature gage or your engine oil pressure gage may be showing a reading in the warning zone When the CHECK GAGES light comes on you will also hear a warning tone The tone and the light...

Page 120: ...ess fuel to fill up than the gage indicated If you have a diesel engine also see your Caterpillar Operation Maintenance Manual Air Pressure Gage If Equipped If your vehicle has air brakes this gage at...

Page 121: ...vacuum on the scale the filter should be replaced After replacing the filter reset the gage by pressing in the yellow reset pin at the bottom of the gage If you have a diesel engine also see your Cat...

Page 122: ...particular systems supplied with your vehicle 3 2 Comfort Controls 3 5 Air Conditioning 3 5 Heating 3 6 Defogging and Defrosting 3 6 Ventilation System 3 7 Audio Systems 3 7 Setting the Clock 3 8 AM...

Page 123: ...Defog This setting divides the airflow between the floor outlets and the windshield defroster vent Some of the air goes to the floor as well Temperature Lever The bottom lever lets you select the temp...

Page 124: ...or Bar The bar under your system display lets you select the temperature of the air coming into the passenger area of your vehicle Press COLD for cooler air and press HOT for warmer air Release the ba...

Page 125: ...og This setting operates the defogger Air comes out near the bottom of the windshield and at your front side windows Floor This setting sends most of the airflow through the floor outlets The rest of...

Page 126: ...conditioner develops high system pressure it will automatically go into the MAX mode and REC will light on your display The A C system will remain in the MAX mode even if you press the MAX button unti...

Page 127: ...hrough the air intake using the fan Outside air can be drawn in when the vehicle is stationary or moving at low speed Air comes in through four vents in the instrument panel and is exhausted through t...

Page 128: ...e flow of air or close the vents altogether When you close a vent it will increase the flow of air coming out of any vents that are open If your vehicle does not have air conditioning there are air ve...

Page 129: ...n Finding a Station AM FM Press this button to switch between AM and FM The display shows your selection DOWN UP Press UP to increase the frequency of a radio station and DOWN to decrease the frequenc...

Page 130: ...ic memory You can set up to 12 stations six AM and six FM by performing the following steps 1 Turn the radio on 2 Press AM FM to select a band 3 Press and hold SET SET will appear on the display and w...

Page 131: ...s player To load a cassette tape hold the cassette with the tape to the right Then insert the cassette tape Tape direction is displayed by the lighted arrow To change the tape direction press the FF b...

Page 132: ...and harmful to your hearing Take precautions by adjusting the volume control on your radio to a safe sound level before your hearing adapts to it To help avoid hearing loss or damage do the following...

Page 133: ...mal for the cassette to eject because your unit is equipped with a broken tape detection feature and a cleaning cassette may appear as a broken tape If the cleaning cassette ejects insert the cassette...

Page 134: ...ving 4 2 Defensive Driving 4 3 Drunken Driving 4 6 Control of a Vehicle 4 6 Braking 4 10 Steering 4 12 Off Road Recovery 4 12 Passing 4 14 Loss of Control 4 15 Driving at Night 4 17 Driving in Rain an...

Page 135: ...ventable of accidents Yet they are common Allow enough following distance It s the best defensive driving maneuver in both city and rural driving You never know when the vehicle in front of you is goi...

Page 136: ...imates nearly half the adult population choose never to drink alcohol so they never drive after drinking For persons under 21 it s against the law in every U S state to drink alcohol There are good me...

Page 137: ...inking will have a somewhat lower BAC level There is a gender difference too Women generally have a lower relative percentage of body water than men Since alcohol is carried in body water this means t...

Page 138: ...right answer What if there s an emergency a need to take sudden action as when a child darts into the street A person with even a moderate BAC might not be able to react quickly enough to avoid the co...

Page 139: ...up your foot and do it That s reaction time Average reaction time is about 3 4 of a second But that s only an average It might be less with one driver and as long as two or three seconds or more with...

Page 140: ...er assist is used up it may take longer to stop and the brake pedal will be harder to push Hydraulic Brake Systems If your engine stops running or if your primary brake system stops working your vehic...

Page 141: ...this test is going on This is normal If there s a problem with the anti lock brake system this warning light will stay on See Anti Lock Brake System Warning Light in the Index Let s say the road is w...

Page 142: ...the brake pedal or always decrease stopping distance If you get too close to the vehicle in front of you you won t have time to apply your brakes if that vehicle suddenly slows or stops Always leave e...

Page 143: ...on the condition of your tires and the road surface the angle at which the curve is banked and your speed While you re in a curve speed is the one factor you can control Suppose you re steering throu...

Page 144: ...ble collision Then steer around the problem to the left or right depending on the space available Since your vehicle has anti lock brakes you don t need to release the brakes to maintain steering cont...

Page 145: ...around the vehicle ahead then goes back into the right lane again A simple maneuver Not necessarily Passing another vehicle on a two lane highway is a potentially dangerous move since the passing vehi...

Page 146: ...rt that more than makes up for the distance you would lose by dropping back And if something happens to cause you to cancel your pass you need only slow down and drop back again and wait for another o...

Page 147: ...ation skid too much throttle causes the driving wheels to spin A cornering skid and an acceleration skid are usually best handled by easing your foot off the accelerator pedal Of course traction is re...

Page 148: ...igue Here are some tips on night driving D Drive defensively D Don t drink and drive D Since you can t see as well you may need to slow down and keep more space between you and other vehicles D Slow d...

Page 149: ...When you are faced with severe glare as from a driver who doesn t lower the high beams or a vehicle with misaimed headlamps slow down a little Avoid staring directly into the approaching headlamps Ke...

Page 150: ...t wet suddenly when your reflexes are tuned for driving on dry pavement The heavier the rain the harder it is to see Even if your windshield wiper blades are in good shape a heavy rain can make it har...

Page 151: ...y to avoid puddles But if you can t try to slow down before you hit them 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...

Page 152: ...oad If you can see reflections from trees telephone poles or other vehicles and raindrops dimple the water s surface there could be hydroplaning Hydroplaning usually happens at higher speeds There jus...

Page 153: ...warning signs and otherwise be very cautious about trying to drive through flowing water Some Other Rainy Weather Tips D Turn on your low beam headlamps and your marker and clearance lamps if your ve...

Page 154: ...ry trip D Larger vehicles can t be driven everywhere smaller ones can There are low underpasses truck routes and other special situations Usually these are well marked so be sure to watch for the sign...

Page 155: ...ramp that leads to the freeway If you have a clear view of the freeway as you drive along the entrance ramp you should begin to check traffic Try to determine where you expect to blend with the flow T...

Page 156: ...in falling asleep at the wheel Call it highway hypnosis lack of awareness or whatever When you drive the vehicle for a long distance there is something about an easy stretch of road with the same scen...

Page 157: ...tem and transmission These parts can work hard on mountain roads D Know how to go down hills The most important thing to know is this let your engine do some of the slowing down Shift to a lower gear...

Page 158: ...p cool your engine and transmission and you can climb the hill better D Stay in your own lane when driving on two lane roads in hills or mountains Don t swing wide or cut across the center of the road...

Page 159: ...nd 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 Be sure you pro...

Page 160: ...f you accelerate too fast the drive wheels will spin and polish the surface under the tires even more D Whatever your braking system allow greater following distance on any slippery road D Watch for s...

Page 161: ...mon help and keep yourself and your passengers safe D Turn on your hazard flashers D Tie a red cloth to your mirror arm to alert police that you ve been stopped by the snow D Put on extra clothing or...

Page 162: ...it go a little faster than just idle That is push the accelerator slightly This uses less fuel for the heat that you get and it keeps the battery or batteries charged You will need a well charged bat...

Page 163: ...the front and rear axles called Gross Axle Weight Rating GAWR To find out the actual loads on your front and rear axles you need to go to a weigh station and weigh your vehicle Your dealer can help yo...

Page 164: ...go as fast as the vehicle goes If you have to stop or turn quickly or if there is a crash they ll keep going CAUTION Things you put inside your vehicle can strike and injure people in a sudden stop or...

Page 165: ...trument panel Together these switches can control PTO engagement and engine speeds Engaging PTO To activate and engage the PTO use the following steps 1 Stop your vehicle 2 Shift the transmission to N...

Page 166: ...d 1 the factory default setting of 1 400 rpm Press in the PTO DOWN SET button again to return the engine speed to the PTO standby speed D Move the PTO UP lever from the on position all the way to PTO...

Page 167: ...ld the switch there until you reach the desired speed then release the switch To increase the speed in small amounts briefly move the switch to PTO UP R A Each time you do this the idle speed will inc...

Page 168: ...azard Warning Flashers 5 4 Other Warning Devices 5 5 Jump Starting 5 11 Towing Your Vehicle 5 19 Engine Overheating 5 21 Cooling System Gasoline Engines 5 28 Cooling System CaterpillarR Diesel Engine...

Page 169: ...n and off The hazard flasher switch is located on the steering column Press the button in to make your front and rear turn signal lamps flash on and off Your hazard warning flashers work no matter wha...

Page 170: ...panel usually to the left of and below the steering column Pull the switch out to make your front and rear turn signal lamps flash on and off A light next to the switch will also flash Push it back i...

Page 171: ...n the hazard lever until it locks into place It works no matter what position your key is in and even if the key isn t in To turn off the flasher move the turn signal lever either up or down Then move...

Page 172: ...tricity to burn you If you don t follow these steps exactly some or all of these things can hurt you NOTICE Ignoring these steps could result in costly damage to your vehicle that wouldn t be covered...

Page 173: ...e vehicles aren t touching each other If they are it could cause a ground connection that you don t want You wouldn t be able to start your vehicle and the bad grounding could damage the electrical sy...

Page 174: ...e place with water and get medical help immediately CAUTION Fans or other moving engine parts can injure you badly Keep your hands away from moving parts once the engine is running 5 Check that the ju...

Page 175: ...a remote positive terminal if the vehicle has one 8 Now connect the black negative cable to the negative terminal of the good battery Use a remote negative terminal if the vehicle has one Don t let t...

Page 176: ...e with the good battery and run the engine for one to two minutes If your vehicle has the high idle option use it 11 Try to start the vehicle with the dead battery If it won t start after a few tries...

Page 177: ...Positive Terminal To disconnect the jumper cables from both vehicles do the following 1 Disconnect the black negative cable from the vehicle that had the dead battery 2 Disconnect the black negative...

Page 178: ...ON Continued D Working on air brakes without first using the release studs to compress the springs can lead to injury Never work on the air brakes chambers without first using the release studs to com...

Page 179: ...them Here are specific towing instructions Towing Your Vehicle From the Front Front Wheels Off the Ground Before Towing Block the rear wheels of the disabled vehicle On vehicles with air brakes relea...

Page 180: ...ft Chain C Front Axle 3 Place a 6 x 6 x 5i hardwood beam underneath and slightly behind the front spring shackle brackets 4 Connect lift chains to the tow bar and raise the tow bar until lift chain sl...

Page 181: ...eath and slightly behind the front spring shackle brackets as previously shown 3 Connect the lift chains to the tow bar and take up the slack in the chains until the tow bar is within 4 of the front b...

Page 182: ...the ground Remove the rearward propshaft Tandem Drive Rear Axle Both Axles on the Ground Due to Type of Suspension or Attached Load Disconnect the propshaft at the forward tandem axle Secure the props...

Page 183: ...nect the propshaft at the rear axle forward axle on tandem axle models Secure the propshaft to the frame or crossmember If there is damage or suspected damage to the axle s remove the axle shafts Cove...

Page 184: ...sure from both systems the parking brakes will have automatically engaged The tow operator can release the brakes manually by using the following steps Then your vehicle can be towed with all wheels o...

Page 185: ...wise several turns to release the brakes Follow the same procedure to release the other brake 7 At the repair facility apply air pressure of at least 70 psi 480 kPa to the brake chambers either from a...

Page 186: ...ngine if you see or hear steam coming from it Just turn it off and get everyone away from the vehicle until it cools down Wait until there is no sign of steam or coolant before you open the hood If yo...

Page 187: ...open the window as necessary 3 If you re in a traffic jam shift to NEUTRAL N otherwise shift to the highest gear while driving AUTOMATIC OVERDRIVE B or DRIVE D for automatic transmissions 4 If climbi...

Page 188: ...e Specialty Hood A Coolant Recovery Tank B Radiator Pressure Cap C Engine Fan Sloped Hood A Coolant Recovery Tank B Engine Fan C Radiator Pressure Cap If the coolant inside the coolant recovery tank i...

Page 189: ...he cooling system CAUTION Heater and radiator hoses and other engine parts can be very hot Don t touch them If you do you can be burned Don t run the engine if there is a leak If you run the engine it...

Page 190: ...but the coolant level isn t at or above the HOT LEVEL mark on the vehicle with the specialty hood or at or above the COLD LEVEL mark on the vehicle with the sloped hood add a 50 50 mixture of clean d...

Page 191: ...ne glycol and it will burn if the engine parts are hot enough Don t spill coolant on a hot engine When the coolant in the coolant recovery tank is at the HOT LEVEL mark on the vehicle with the special...

Page 192: ...ey 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 Wait...

Page 193: ...ntil it first stops Don t press down while turning the pressure cap If you hear a hiss wait for that to stop A hiss means there is still some pressure left 2 Then keep turning the pressure cap but now...

Page 194: ...n feel the upper radiator hose getting hot Watch out for the engine cooling fan s 7 By this time the coolant level inside the radiator filler neck may be lower If the level is lower add more of the pr...

Page 195: ...B Coolant Surge Tank If the coolant inside the coolant surge tank is boiling don t do anything else until it cools down The coolant level should be at COLD ADD or higher If it isn t you may have a le...

Page 196: ...ms to be no leak start the engine again The fan speed should increase when idle speed is doubled by pushing the accelerator pedal down If it doesn t your vehicle needs service Turn off the engine How...

Page 197: ...e cooling system including the coolant surge tank pressure cap is hot Wait for the cooling system and coolant surge tank pressure cap to cool if you ever have to turn the pressure cap CAUTION Adding o...

Page 198: ...ended coolant CAUTION 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 Don t spill coolant on a hot engin...

Page 199: ...5 32 2 Then keep turning the cap but now push down as you turn it Remove the pressure cap 3 Then fill the coolant surge tank with the proper coolant mixture up to the COLD FULL mark...

Page 200: ...getting hot Watch out for the engine fan By this time the coolant level inside the coolant surge tank may be lower If the level is lower add more of the proper mixture to the coolant surge tank until...

Page 201: ...out while you re driving especially if you maintain your tires properly If air goes out of a tire it s much more likely to leak out slowly But if you should ever have a blowout here are a few tips abo...

Page 202: ...as quite low on air the tire can have a sudden air out This could cause you to lose control of the vehicle and have a serious crash Don t refill a flat or very low tire with air without first having t...

Page 203: ...parts of your vehicle as well as the tires If you spin the wheels too fast while shifting your transmission back and forth you can destroy your transmission Rocking Your Vehicle To Get It Out First tu...

Page 204: ...Diesel Engines 6 19 Engine Air Cleaner Filter 6 21 Automatic Transmission Fluid 6 22 Manual Transmission Fluid 6 23 Rear Axle 6 23 Rear Axle Shift Motor Option 6 24 Engine Coolant Gasoline Engine 6 28...

Page 205: ...n To order the proper service manual see Service and Owner Publications in the Index You should keep a record with all parts receipts and list the mileage and the date of any service work you perform...

Page 206: ...verned speed of the vehicle without getting the necessary information from your dealer CAUTION Continued CAUTION Continued Winter Fronts Grille Covers or Obstructions Winter fronts grille covers or ot...

Page 207: ...e or drive uphill is considered normal This does not indicate a problem exists or that a higher octane fuel is necessary Gasoline Specifications It is recommended that gasoline meet specifications whi...

Page 208: ...l gasolines in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming allowing your emission control system to work properly You sh...

Page 209: ...u could be burned If you ever try to drain water from your fuel keep sparks flames and smoking materials away from the mixture NOTICE If there is water in your diesel fuel and the weather is warm or h...

Page 210: ...by use of improper fuel wouldn t be covered by your warranty To check on fuel availability ask an auto club or contact a major oil company that does business in the country where you ll be driving Fi...

Page 211: ...nd is more likely in hot weather Open the fuel filler cap slowly and wait for any hiss noise to stop Then unscrew the cap all the way When you put the cap back on turn it to the right clockwise until...

Page 212: ...ehicle in a vehicle s trunk pickup bed or on any surface other than the ground D Bring the fill nozzle in contact with the inside of the fill opening before operating the nozzle Contact should be main...

Page 213: ...the hood forward pull out on each of the hood latches If the hood is equipped with hood access panels make sure the panel latches are locked down before lifting the hood open Then take the hand holds...

Page 214: ...he cables will support it If your vehicle has the optional hood access panels you can easily get to one side of the engine or the other as you need to Pull out on the top of each hood latch Then push...

Page 215: ...federal noise emission standards for vehicles with a Gross Vehicle Weight Rating GVWR of more than 10 000 lbs 4 536 kg The Maintenance Schedule provides information on maintaining the noise control s...

Page 216: ...t of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Insulation D Removal of the noise shields or any underhoo...

Page 217: ...on level ground The engine oil dipstick is located on the driver s side of the engine compartment Turn off the engine and give the oil several minutes to drain back into the oil pan If you don t the...

Page 218: ...For engine oil crankcase capacity see Capacities and Specifications in the Index NOTICE Don t add too much oil If your engine has so much oil that the oil level gets above the cross hatched area that...

Page 219: ...te API Do not use any oil which does not carry this starburst symbol If you change your own oil be sure you use oil that has the starburst symbol on the front of the oil container If you have your oil...

Page 220: ...symbol are all you will need for good performance and engine protection When to Change Engine Oil GM Oil Life Systemt Your vehicle has a computer system that lets you know when to change the engine oi...

Page 221: ...nds the system is reset If the light does not display for five seconds you will need to repeat the steps What to Do with Used Oil Used engine oil contains certain elements that may be unhealthy for yo...

Page 222: ...cleaner filter See Scheduled Maintenance in the Index Gasoline Engine Caterpillar Diesel Engine Your gasoline or diesel engine has a restriction indicator that lets you know when the engine air cleane...

Page 223: ...and Indicators in the Index CAUTION Gasoline Engines Only Operating the engine with the air cleaner filter off can cause you or others to be burned The air cleaner not only cleans the air it stops fl...

Page 224: ...r automatic transmission filter requires periodic replacement Consult the Allison Automatic Transmission Operator s Manual that came with the vehicle for proper change intervals Automatic Transmission...

Page 225: ...re that the lubricant level is up to the bottom of the fill opening On heavy duty transmissions an inch of oil level equals about one gallon of fluid 3 If the fluid level is good install the plug and...

Page 226: ...ance Schedule to determine what kind of lubricant to use See Recommended Fluids and Lubricants in the Index Rear Axle Shift Motor Option When to Check and Change Fluid If you have an optional air shif...

Page 227: ...nd DEX COOLR coolant will D Give freezing protection down to 34_F 37_C D Give boiling protection up to 252_F 122_C D Protect against rust and corrosion D Help keep the proper engine temperature D Let...

Page 228: ...engine could get too hot but you wouldn t get the overheat warning Your engine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOLR coolant NO...

Page 229: ...6 26 Checking Coolant Coolant Recovery Tank Gasoline Engines Specialty Hood Coolant Recovery Tank Gasoline Engines Sloped Hood...

Page 230: ...level or a little higher on the coolant recovery tank with the gasoline engine or at the COLD FULL mark visible through the surge tank with the diesel engine If this light comes on and stays on it me...

Page 231: ...ixture at the recovery tank or the surge tank but be careful not to spill it CAUTION You can be burned if you spill coolant on hot engine parts Coolant contains ethylene glycol and it will burn if the...

Page 232: ...oolant loss and possible engine damage from overheating Be sure the arrows on the cap line up with the top of the overflow tube Surge Tank Pressure Cap Diesel Engines The surge tank pressure cap must...

Page 233: ...ermine what kind of fluid to use see Recommended Fluids and Lubricants in the Index NOTICE When adding power steering fluid or making a complete fluid change always use the proper fluid Failure to use...

Page 234: ...ll NOTICE D When using concentrated washer fluid follow the manufacturer s instructions for adding water D Don t mix water with ready to use washer fluid Water can cause the solution to freeze and dam...

Page 235: ...fluid Brake fluid could spill on the hot engine and it can catch fire You could be burned and your vehicle could be damaged See Checking Brake Fluid in this section Checking Brake Fluid Apply the brak...

Page 236: ...is could cause a crash Always use the proper brake fluid NOTICE D Using the wrong fluid can badly damage brake system parts For example just a few drops of mineral based oil such as engine oil in your...

Page 237: ...a rapid increase in pedal travel This could be a sign of brake trouble Brake Adjustment Every time you make a brake stop your brakes adjust for wear Replacing Brake System Parts The braking system on...

Page 238: ...ull pressure check your air pressure gage It should read at least 100 psi 692 kPa Moisture Ejector Option If you have air brakes with a moisture ejector the valve automatically ejects moisture from th...

Page 239: ...n fluid See Maintenance Schedule in the Index How to Check and Add Fluid Be sure the parking brake is firmly set To check the fluid level look at the MAX and MIN lines on the side of the reservoir If...

Page 240: ...ree travel Your Maintenance Schedule has more on this If your clutch ever needs service be sure to use only genuine GM clutch replacement parts Chassis Lubrication Your Maintenance Schedule provides a...

Page 241: ...6 38 Single Axle Models...

Page 242: ...nd Hinges Apply chassis lubricant 6 Slack Adjuster n One fitting 7 Brake Cam Roller Pins at interface of pin and shoe n Apply engine oil 8 Front Steering Knuckles One fitting each side lower bushing h...

Page 243: ...with GM Part No 1051344 Wheel Bearing Lubricant Two fittings each joint 1610 Series and larger lubricate with GM Part No 1051344 Wheel Bearing Lubricant 19 Rear Wheel Bearing Hand pack or lubricate 2...

Page 244: ...icate with GM Part No 1051344 Wheel Bearing Lubricant 4 Brake Shoe Roller Pins Apply engine oil at pin to shoe joint only 5 Rear Spring Pin One fitting each side 6 Wheel Bearings Hand pack or lubricat...

Page 245: ...u 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 b...

Page 246: ...he Index for more information Replacement blades come in different types and are removed in different ways Here s how to remove the Shephard s Hook type 1 Pull the windshield wiper arm away from the w...

Page 247: ...er emission canister or other components are in there 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 T...

Page 248: ...ponent box See Maintenance Schedule in the Index for recommended service intervals Primary Fuel Filter and Water Separator Option If you have a Caterpillar diesel engine you may have this spin on filt...

Page 249: ...out first See Engine Oil in the Index for proper disposal procedures If you have this filter you will not have a primary filter Automatic Ether Injection System Option If your diesel engine vehicle ha...

Page 250: ...then remove it Be careful not to allow any dirt or water to get into the oil Add enough of the recommended oil to bring it up to the level mark that you ll see on the glass Refer to your Maintenance S...

Page 251: ...serious accident See Loading Your Vehicle in the Index CAUTION Continued CAUTION Continued D Underinflated tires pose the same danger as overloaded tires The resulting accident could cause serious inj...

Page 252: ...g D Bad wear D Bad handling D Bad fuel economy NOTICE Continued NOTICE Continued If your tires have too much air overinflation you can get the following D Unusual wear D Bad handling D Rough ride D Ne...

Page 253: ...n a dual wheel setup generally wears faster than the inner tire Your tires will wear more evenly and last longer if you rotate the tires periodically If you re going to be doing a lot of driving on hi...

Page 254: ...e radial and bias belted tires the vehicle may not handle properly and you could have a crash Be sure to use the same type of tires all around When you replace tires make sure they are the same size l...

Page 255: ...icle causing a crash All wheel nuts must be properly tightened Follow the rules in this section to be sure they are This section lets you know how often to check the tightness of the wheel nuts on you...

Page 256: ...these wheels have right hand threads 1 With intermittent pilot pads position a pad at 12 o clock to center the wheel and reduce run out 2 Put the tire and rim assembly on the axle hub Install the oute...

Page 257: ...cause a crash If any stud is damaged because of a loose running wheel it could be that all of the studs are damaged To be sure replace all studs on the wheel If the stud holes in a wheel have become...

Page 258: ...n check nut tightness on all wheels with a torque wrench after your first 100 miles 160 km and then every 1 000 miles 1 600 km after that Be sure to repeat this service whenever you have a tire remove...

Page 259: ...ing limits than the original wheels and tires doesn t change the GAWR or the GVWR of your vehicle NOTICE The wrong wheel can cause trouble in bearing life brake cooling speedometer odometer calibratio...

Page 260: ...one D Paint Thinner D Turpentine D Lacquer Thinner D Nail Polish Remover They can all be hazardous some more than others and they can all damage your vehicle too Don t use any of these unless this man...

Page 261: ...the section use a sponge to remove any excess cleaner 6 Wipe cleaned area with a clean water dampened towel or cloth 7 Wipe with a clean cloth and let dry Special Fabric Cleaning Problems Stains caus...

Page 262: ...s of the instrument panel Sprays containing silicones or waxes may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions Cleani...

Page 263: ...Wiper Blades If the windshield is not clear after using the windshield washer or if the wiper blade chatters when running wax sap or other material may be on the blade or windshield Clean the outside...

Page 264: ...l removing all soap residue completely You can get GM approved cleaning products from your dealer See Appearance Care and Materials in the Index Don t use cleaning agents that are petroleum based or t...

Page 265: ...ossible If necessary use non abrasive cleaners that are marked safe for painted surfaces to remove foreign matter Exterior painted surfaces are subject to aging weather and chemical fallout that can t...

Page 266: ...off immediately after application Don t take your vehicle through an automatic vehicle wash that has silicon carbide tire cleaning brushes These brushes can also damage the surface of these wheels Cle...

Page 267: ...hop Underbody Maintenance Chemicals used for ice and snow removal and dust control can collect on the underbody If these are not removed accelerated corrosion rust can occur on the underbody parts suc...

Page 268: ...6 65 GM Vehicle Care Appearance Materials...

Page 269: ...ements is on your GVW Rating label Here is what each one means TRUCK SERVICE A vehicle made to carry property or special equipment It is made for uniform frame loading That includes using the vehicle...

Page 270: ...the light switch An electrical overload will cause the lights to go on and off or in some cases to remain off If this happens have your headlamp wiring checked right away Windshield Wiper Fuses The w...

Page 271: ...aped to the wiring harness near the hydraulic brake booster and one near the generator also taped to the wiring harness There are two circuit breaker fuse blocks in your vehicle the instrument panel c...

Page 272: ...odule Diesel Engines Canister Purge Electronic Throttle Control Mass Air Flow Engine Control Module Gasoline Engines Transmission Shift Solenoid Gasoline Engines B U IGN3 Fuel Filter Relay Blower Moto...

Page 273: ...Brake Solenoid FUEL Heated Fuel Filter Diesel Engines or Fuel Pump Gasoline Engines Name Circuits Protected AXLE Heated Mirrors Radiator Shutters Two Speed Axle Motor Two Speed Axle Switch MKR LP Roo...

Page 274: ...the instrument panel circuit breaker block If no circuit breakers are out there the problem could be in the maxi fuse block This block uses blade type fuses It s on the upper rear part of the engine...

Page 275: ...6 72 Vehicles with Hydraulic Brakes Vehicles with Air Brakes...

Page 276: ...Brake Brake Pump Motor HYD ABS Hydraulic ABS AIR ABS Air ABS ABS Power Relay Trailer Wiring Name Circuits Circuit Breakers Protected PWR WDO LCKS Window Door Locks PARK BRK Parking Brake Motor TRLR T...

Page 277: ...filter element is changed Capacities given are approximate keep level within the operating range Do not operate with fluid level below the ADD line Engine Capacity Quarts Liters 7 2L 21 19 0 8 1L 6 5...

Page 278: ...c transmissions see the Allison Automatic Transmission Operator s Manual for oil check and maintenance information Manual Transmission Pints Liters RT6609 12 5 5 9 RT8709B 25 1 11 8 Manual Transmissio...

Page 279: ...re approximate Tandem Axles Lubricant Pints Liters DS344 front 31 0 14 5 RS344 rear 28 0 13 2 DS454 front 29 0 15 1 RS454 rear 28 0 13 2 DS404 DS404P front 31 0 14 5 RS404 rear 28 0 13 0 DT402P front...

Page 280: ...ting They are subject to later change If a part listed here isn t the same as the part in your vehicle when it was built or if you have any questions please contact your GM Truck dealer Allison Transm...

Page 281: ...54 Air Cleaner Donaldson P522606 ACDelcoR A1518C Fuel Filter ACDelcoR 915 Primary ACDelcoR GF626 Secondary Fuel Filter CATR 1R0751 Pressure Caps RC 54 GM Part No 15997145 Optional Davco K28 D350921 sp...

Page 282: ...our vehicle needs these services to retain its safety dependability and emission control performance 7 2 Introduction 7 4 Part A Scheduled Maintenance Services 7 5 Scheduled Maintenance 7 25 Part B Ow...

Page 283: ...t 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 To help protect...

Page 284: ...ols and equipment for the job If you have any doubt have a qualified technician do the work If you want to get the service information see Service and Owner Publications in the Index Part B Owner Chec...

Page 285: ...ice needs you ll know that GM trained and supported service people will perform the work using genuine GM parts The proper fluids and lubricants to use are listed in Part C Make sure whoever services...

Page 286: ...necessary The Footnotes at the end of this Maintenance Schedule further explain maintenance services See Scheduled Maintenance Supplements earlier in this section 100 Miles 160 km j Wheel stud nut se...

Page 287: ...ssis lubrication service or every 6 months whichever occurs first 12 j Lubricate door hinge pins and rollers with engine oil j Wheels and tires service 15 46 j Hydraulic brake service or every 6 month...

Page 288: ...or every 6 months whichever occurs first 22 j Hydraulic parking brake service or every 6 months whichever occurs first 8 j Clutch pedal free travel service 10 j Clean air brake application valve or ev...

Page 289: ...er service or every 2 months whichever occurs first 41 j Trailer brake hand control valve service or every 3 months or 900 hours whichever occurs first 42 27 000 Miles 45 000 km j Check Oil Life Monit...

Page 290: ...ck fluid levels or every 3 months whichever occurs first 1 2 6 j Chassis lubrication service or every 6 months whichever occurs first 12 j Inspect door hinge pins and bushings and replace as necessary...

Page 291: ...raulic parking brake service or every 6 months whichever occurs first 8 j Clutch pedal free travel service 10 45 000 Miles 75 000 km j Check Oil Life Monitor If engine oil and filter are changed reset...

Page 292: ...axle air shift motor service 11 j Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs first j Air brake chamber service or every 2 months whic...

Page 293: ...very 3 months whichever occurs first 1 2 6 60 000 Miles 100 000 km j Check Oil Life Monitor If engine oil and filter are changed reset monitor See Engine Oil in the Index 3 9 j Check fluid levels or e...

Page 294: ...filter are changed reset monitor See Engine Oil in the Index 3 9 j Check fluid levels or every 3 months whichever occurs first 1 2 6 66 000 Miles 110 000 km j Check Oil Life Monitor If engine oil and...

Page 295: ...ts service or every 12 months whichever occurs first 18 j Clutch pedal free travel service 10 j Thermostatically controlled engine cooling fan service 4 20 j Shields and underhood insulation service 4...

Page 296: ...r every 6 months whichever occurs first 12 j Lubricate door hinge pins and rollers with engine oil j Wheels and tires service 15 46 j Hydraulic brake service or every 6 months whichever occurs first 7...

Page 297: ...See Engine Oil in the Index 3 9 j Check fluid levels or every 3 months whichever occurs first 1 2 6 90 000 Miles 150 000 km j Check Oil Life Monitor If engine oil and filter are changed reset monitor...

Page 298: ...ls or every 3 months whichever occurs first 1 2 6 96 000 Miles 160 000 km j Check Oil Life Monitor If engine oil and filter are changed reset monitor See Engine Oil in the Index 3 9 j Check fluid leve...

Page 299: ...the Index 3 9 j Check fluid levels or every 3 months whichever occurs first 1 2 6 100 000 Miles 166 000 km j Change power steering fluid or every 24 months whichever occurs first 13 j Replace power s...

Page 300: ...on warranty or limit recall liability prior to the completion of the vehicle s useful life We however urge that all recommended maintenance services be performed at the indicated intervals and the mai...

Page 301: ...dal by hand until resistance is felt Free travel should be maintained at 1 5 to 2 inches 38 to 51 mm measured at the clutch pedal pad Make checks at 3 000 miles 5 000 km and 6 000 miles 10 000 km and...

Page 302: ...bnormal wear or damage Also check for damaged wheels Replace wheels and or tires as needed 16 Check spring to axle U bolts and shackle bolts for proper torque See the service manual for torque sequenc...

Page 303: ...tions and fasteners or replace parts as required 26 Evaporative Control System Service if equipped Check all fuel and vapor lines and hoses for proper connections and any damage or every 24 months whi...

Page 304: ...wiring Check brake pedal for excessive free play or travel or every 6 months whichever occurs first and have serviced if needed Check brakes more often if driving habits and conditions result in frequ...

Page 305: ...ue values at 1 000 miles 1 600 km Thereafter tighten them 1 000 miles 1 600 km after each time the wheel is removed See Tightening the Wheel Nuts in the Index 47 Service is required now if you operate...

Page 306: ...il if necessary See Engine Oil in the Index for further details Engine Coolant Level Check Check the engine coolant level and add DEX COOLR coolant mixture if necessary See Engine Coolant in the Index...

Page 307: ...door weatherstrips and rubber cap bumpers should also be lubricated Part C tells you what to use More frequent lubrication may be required when exposed to a corrosive environment Parking Brake Check...

Page 308: ...ssure and check system for leaks Any of these conditions could indicate the need for brake system inspection and or service Engine Cooling System Service Inspect the hoses and have them replaced if th...

Page 309: ...ps identification and clearance lamps taillamps brake lamps turn signals backup lamps and hazard warning flashers Have headlamp aim checked at once if beams seem improperly aimed Glass Mirrors Lamps a...

Page 310: ...e mud and other debris can collect Sediment packed in closed areas of the frame should be loosened before being flushed Engine Cover Check Check that the cab s engine cover and seal if equipped are no...

Page 311: ...rpillar Diesel Engine See the CaterpillarR Operation Maintenance Manual for engine oil recommendations USAGE FLUID LUBRICANT Engine Coolant Gasoline Engine DURAMAXt Diesel 50 50 mixture of clean drink...

Page 312: ...rt Spring and Caliper Support Key Aeroshell 5 Grease GM Part No 12377969 or equivalent USAGE FLUID LUBRICANT Power Steering System GM Power Steering Fluid GM Part No 1052884 1 pint 1050017 1 quart or...

Page 313: ...e Lubricant for Medium Duty Trucks GM Part No 12345841 or equivalent Rear Axle Shift Motor Lubricant Refrigerant Oil GM Part No 5416939 USAGE FLUID LUBRICANT Propshafts and Splines Wheel bearing lubri...

Page 314: ...e maintenance record charts provided here Any additional information from Owner Checks and Services can be added on the following record pages Also you should retain all maintenance receipts Your owne...

Page 315: ...7 34 Maintenance Record DATE ODOMETER READING SERVICED BY MAINTENANCE PERFORMED...

Page 316: ...7 35 Maintenance Record DATE ODOMETER READING SERVICED BY MAINTENANCE PERFORMED...

Page 317: ...7 36 Maintenance Record DATE ODOMETER READING SERVICED BY MAINTENANCE PERFORMED...

Page 318: ...tions and how to report any safety defects 8 2 Customer Satisfaction Procedure 8 3 Customer Assistance for Text Telephone TTY Users 8 3 Customer Assistance Offices 8 5 Roadside Assistance 8 5 Warranty...

Page 319: ...owner of the dealership or the general manager STEP TWO If after contacting a member of dealership management it appears your concern cannot be resolved by the dealership without further help contact...

Page 320: ...t encourages customers to call the toll free number for assistance If a U S customer wishes to write to Chevrolet the letter should be addressed to Chevrolet Medium Duty Truck s Customer Assistance Ce...

Page 321: ...L de C V Customer Assistance Center Paseo de la Reforma 2740 Col Lomas de Bezares C P 11910 Mexico D F 01 800 508 0000 Long Distance 011 52 53 29 0 800 Roadside Assistance GM Medium Duty Truck s Roads...

Page 322: ...n Your vehicle comes with a separate warranty booklet that contains detailed warranty information REPORTING SAFETY DEFECTS TO THE UNITED STATES GOVERNMENT If you believe that your vehicle has a defect...

Page 323: ...tario K1A 0N5 REPORTING SAFETY DEFECTS TO GENERAL MOTORS In addition to notifying NHTSA or Transport Canada in a situation like this we certainly hope you ll notify us Please call us at 1 800 TO CHEVY...

Page 324: ...ce Schedule for all models In Portfolio Includes a Portfolio Owner s Manual and Warranty Booklet RETAIL SELL PRICE 35 00 Without Portfolio Owner s Manual only RETAIL SELL PRICE 25 00 Current and Past...

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