2003 LSSV Operator Manual Supplement
Contents
1. 6 3 G Government Vehicle Data Plate 5 13 How to Use This Manual uuesrneennnennnnnennnnnnennee nenn ii If You re Stuck in Sand Mud Ice or Snow 4 5 Using the Clevis Towing Provisions 4 5 Front Clevis Towing Provisions 4 6 Rear Clevis Towing Provisions 4 6 Maximum Allowable Loads On Each Clevis Towing Shackle 4 7 Inflation Tire Pressure uemennssennnnnennn nennen 5 12 Installing the Pintle Hitch 44444 nennen 4 10 Interior Lamps catre 3 6 Topper Dome Lamp nn 3 6 J Jump AN rc meer 5 3 Jump Starting from a 12 Volt System 5 3 Loading the Vehicle eenne 4 2 4 8 Maintenance Schedule ococcccccicninionconnononncnocanccnorancancnnns 6 2 Front Rear Axle Inspection 6 2 Transfer Case Inspection uuneesseneneennennnne nen 6 2 Fuel Fired Coolant Heater Inspection 6 3 Winch Inspection iuris Naa 6 3 Maximum Allowable Loads on Each Clevis Towing Shagkle ss reiii senn anesan 4 7 Mounting the Weapon ueressnnennennennnnennnnnn nennen nennen 2 8 Multi Mount Winch uerenesnsneennnnnnnnnnnnnnnnen nennen 4 3 O Operating the Pintle Hitch ee eee iannis 4 10 Operating Service and Blackout Lighting 3 4 Permanent Mount Winch Pintle Hitch Operating the Pintle Hitch Installing the Pintle Hitch2. R Rear Axle Vent Tube Filter ue nennen 5 10 Rear Clevis Towing Provisions 2eneennnenn 4 6 Rear Topper Window uueresnenneennnnennennnnnnnnennnn nennen 2 2 Replacement Bulbs 42 ern 5 11 Restr ints u a 1 3 Rear Safety SIAP oia nenne 1 3 S Safety Warnings and Symbols iii Service and Blackout Lighting 0 ce eceeeeeeeeeeeeeeeeees 3 2 Side Topper WINdOW ai 4 4 2 2 Shipping Data Plate eee eee eeeeeeeeeneeeeeeaes 5 13 Sliding Rear Window eeresesenneennnnenneesnnnennnnnnnnennnnnn 2 3 Starting and Operating the Vehicle 2 3 Starting the Engine nn 2 3 Storage ANE AS co aa das 25 Cargo Cover Soft TOp nunesseesennennennnnennn nennen nen 2 5 Rolling Up the Side Panels uurn 2 5 Storing the Cargo Cover unnenesnssennennesnnennnnnnnnnen 2 5 Slave Stalin 5 8 Changing a Flat Tire a Inflation Tire PresSur8 oococconocccnoccconoccnnonnononcnoninonnos 5 12 TINA 4 8 Towing the Vehicle 4 8 Towingia Iraller 2 2422 ehe 4 8 Loading the Vehicle 4 ses 4 8 Weight of the Trailer 14220 4 9 Trailer Connector Adaptor ennenn 4 11 Trailer Wiring Connector uensesesrneenennnnennnnnnn nennen nen 4 11 Transfer Case Inspection urneserneeesnnnnennnennnn nennen 6 2 Transfer Case Vent Tube Filter 5 10 MOOD SCANS caia iia 1 2 Troop Seat Operation
3. unnesesnneesnennnnennnnnennnnnn nen 1 2 Folding the Seats DOWN irisse isiin ai 1 2 Folding the Seats UP oooooncocicccinconociccnnocanoncnrnnanananon 1 3 24 Volt Circuit Breakers riinan arns 5 14 24 Volt POWer SOUECO cocina 5 14 24 V Ol Gage cir 3 8 U Underhood Component Locator 5 2 UUM SENTING es raano saraaa aaen 5 3 Jump Starting from a 12 Volt System 5 3 Slave St rlind aora dio 5 8 Using the Clevis Towing Provisions ueseeneeeenen 4 5 Using JPE asa Fuel 4 2 Vehicle Damage Warnings umnnneen nennen neennnnennn nennen iii Vehicle Information ccceccececceceececeeeeesceeeeeeeeeeeaeeeeeeeees 5 13 Shipping Data Plate nene 5 13 Government Vehicle Data Plate 5 13 Vent Rilleis aa sHersee ehem 5 10 Rear Axle Vent Tube Filter 5 10 Transfer Case Vent Tube Filter 5 10 Front Axle Vent Tube Filter 5 10 W Warning Lights Gages and Indicators 3 8 24 Volt Gage iii ies 3 8 Weapons Mount ee 2 7 Weapons Mount Floor Mount 2 7 Weapons Mount Cab Mount 2 8 Weight of the Tailers iann rada ais 4 9 Winch Accessory Kit ccccecceeceeeeeecceeeeeeeseeeeeeseaeeeeeeaeeeeees 4 4 Winch Inspection nme teneescniteceeteeteneed 6 3 SATR E NAEL EEE EE T TOEA EA 4 3 Multi MOUN iieis ea 4 3 WINCH S
4. 5 13 Vent FiltersS oooooocococococcncnononcnnnononononononononos 5 10 Shipping Data Plate nen 5 13 Rear Axle Vent Tube Filter 5 10 Government Vehicle Data Plate 5 13 Transfer Case Vent Tube Filter 5 10 Front Ae Ver Tube Eller cs 5 10 Electrical System ed 5 14 Fuses and Circuit Breakers 5 14 Replacement BulbS oooooooooocccccocooccccccccccconancccnnnnnnnos 5 11 Tires a a 5 11 Changing a Flat TilB ooononioninninncinnnnonocnnccnnenncnnns 5 11 Inflation Tire Pressure een 5 12 5 1 Underhood Component Locator NETZ E AN dl dalai i A AAA AN wA A ad P gt Wa rs The following items are military options that may be found on the vehicle A 24 Volt Generator C Circuit Breakers E 24 Volt Battery B 24 Volt Generator Fuses D 24 Volt Relay 5 2 Jump Starting If the battery or batteries on the vehicle have run down and the vehicle will not start you may want to use another vehicle to provide power to start the vehicle NATO slave cables are the only recommended method for 24 volt jump starting of the vehicle You should only use NATO slave cables to jump start similar vehicles Heavy duty jumper cables can be used to jump start the 12 volt system See Jump Starting from a 12 volt System Jump Starting from a 12 Volt System Batteries can hu
5. Install the latch pin F Installing the Pintle Hitch 1 Remove any debris from the inside of the receiver 2 Push the pintle hitch E into the receiver 3 Install the retaining pin B into the receiver and the pintle hitch E 4 Install the spring clip A into the retaining pin B Trailer Wiring Connector On the military bumper the NATO standard 12 pin trailer lamp and brake connector is located on the rear bumper between the right clevis tie down and the pintle hitch On the factory bumper the NATO standard 12 pin trailer lamp and brake connector is located on the rear trailer hitch to the left of the pintle hitch When connecting a trailer wiring harness to the connector make sure the dog ears of the connector are properly aligned when inserting it into the connector Trailer Connector Adapter When connecting to a commercial trailer with an 8 pin connector the adapter must be used This adapter allows you to connect an 8 pin trailer wiring harness into the vehicle s 12 pin connector 4 11 NOTES 4 12 Section 5 Service and Appearance Care Underhood Component Locator 5 2 Appearance Care 444040nsnnnnnnnnnnennnnennnnnenn 5 12 Engine Compartment Overview uunesneeeeeneenen 5 2 Cleaning the Outside of the Vehicle 5 12 Jump Starting anenee demete anecdote 5 3 Vehicle Information nne eeernne
6. 2003 General Motors Light Service Support Vehicle LSSV Military Truck Owner s Manual Supplement Seats and Restraints Systems 1 1 Troop Se ls rasant i nica 1 2 Restr ints uane nee 1 3 Features and Controls Windows Starting and Operating the Vehicle Fuel Fired Coolant Heater re ern ne 2 4 Storage ANCAS sac aii 2 5 Cargo Tie DOWNS c ccecceeeceeeeeeeeeeeeeteaeeeeeeeenetenees 2 7 Weapons Mosaico 2 7 InstrumentPanel comicos da 3 1 ExtenorLaMpSiccci ainia ainda 3 2 Interior Lamps anne 3 6 Warning Lights Gages and Indicators 3 8 Driving The Vehicle nn 4 1 Your Driving the Road and the Vehicle 4 2 TOWING ansann 4 8 Service and Appearance Care 5 1 Underhood Component Locator 5 2 Vent FIETS econo ic alii e Replacement Bulbs Messi Appearance Care Vehicle Information ssnnnnnnnnnnenn 5 13 Eleciical ste Mirian bake aed 5 14 Maintenance Schedule ee 6 1 Maintenance Schedule ee 6 2 Customer Assistance Information 7 1 Customer Assistance Information 7 2 Index iaa 8 1 The information in this manual pertains to the operation of the vehicle It also contains the vehicle s scheduled maintenance services This manual along with the owner s ma
7. IOA GE s 32 2 4 3 Control of the WiINON i is 4 4 How the Winch Reacts to Load 4 4 Permanent Mount eensenennenneneennen 4 4 Rear TopperWindoW 3 a diia 2 2 Side Topper Window uunersersesenneennennnnnennnnnnnn nen 2 2 Sliding Rear Window uuesernenennnnennennennennn nn 2 3 Your Driving the Road and the Vehicl8 oo oooooncccoconicccnoncccnnnonnnnoonnnnnonnnnonnonoroncnronanononn 4 2 Loading the Vehicle eee 4 2
8. both vehicles involved in the jump start procedure Put the automatic transmission in PARK P Be sure the transfer case is in a drive gear and is NOT in NEUTRAL N 4 Open the hood and locate the battery Find the positive and negative terminals on each 2 Turn off the ignition on both vehicles Unplug battery unnecessary accessories plugged into the cigarette lighter or accessory power outlets Turn off all lamps that are not required as well as radios This will avoid sparks and help save both batteries In addition it could save the radio 5 4 CAUTION Using a open flame near a battery can cause battery gas to explode People have been hurt doing this and some have been blinded Use a flashlight if you need more light Be sure the batteries have enough water You don t need to add water to the Delco Freedom battery or batteries installed in every new GM vehicle But ifa battery has filler caps be sure the right amount of fluid is there If it is low add water to take care of that first If you do not explosive gas could be present Battery fluid contains acid that can burn you Do not get it on you If you accidentally get it in the eyes or on the skin flush the place with water and get medical help immediately Fans or other moving engine parts can injure you badly Keep your hands away from moving part once the engine is running 5 Connect the positive cable to the positive terminal o
9. ce or Snow Using the Clevis Towing Provisions The vehicle is equipped with two clevises on the front and rear ends of the vehicle CAUTION The clevises when used are under a lot of force Always pull the vehicle straight out Never pull on the clevises at a sideways angle The clevises could break off and people could be injured from the chain or cable snapping back When recovering the vehicle you should determine the direction of the recovery by the distance required to free the vehicle and the surrounding terrain Secure the towing cable to both front or rear clevises with a V device to gain an even pull on both anchor points and avoid damage to the vehicle Note Clevises meet MIL 209J for tie down specifications Vehicles do not meet MIL 209J for vehicle lifting 4 5 Front Clevis Towing Provisions Rear Clevis Towing Provisions Factory Bumper Maximum Allowable Loads on Each Clevis Towing Shackle Regular Cab Models Load Direction Weight Fore Aft Front 15 000 Ibs 6 803 kg Fore Aft Rear 15 000 Ibs 6 803 kg Vertical Front 10 000 Ibs 4 535 kg Vertical Rear 7 000 Ibs 3 175 kg Lateral Front 10 000 Ibs 4 535 kg Lateral Rear 5 500 Ibs 2 494 kg Crewcab Models Load Direction Weight O Fore Aft Front 15 000 Ibs 6 803 kg Fore Aft Rear 15 000 Ibs 6 803 kg Vertical Front 10 000 Ibs 4 535 kg Vertical Rear 7 000 Ibs 3 175 kg Lateral Front 10 000 Ibs 4 535 kg La
10. ced as an assembly For bulb replacement refer to the 2003 LSSV Military Trucks Service Manual Supplement Tires Changing a Flat Tire The military heavy duty bumper of the vehicle has an opening A to gain access to the spare tire hoist For more information refer to Changing a Flat Tire in the Index of the 2003 Vehicle Owner s Manual 5 11 Inflation Tire Pressure Tire pressure should be within the manufacturer s recommended range as indicated on the certification tire label which is on the driver s door edge When hauling heavy loads the pressure should be at the maximum allowable pressure Refer to Inflation Tire Pressure in the Index of the 2003 Vehicle Owner s Manual for additional information on tire inflation pressure Appearance Care Cleaning the Outside of the Vehicle Wash the vehicle using only mild soap and water Do not use cleaning agents that are petroleum based or that contain acid or abrasives All cleaning agents should be flushed promptly and not allowed to dry on the surface Do not towel dry or wax the paint surface 5 12 Cleaning the Soft Top Cargo Cover If the cargo cover has deteriorated replace it Refer to cargo cover replacement in the 2003 LSSV Military Trucks Service Manual Supplement The cargo cover is a waterproof welded plastic coated polyester Wash the cover using only mild soap and water Do not use cleaning agents that are petroleum based or that contain acid
11. cessory power outlets Turn off all lamps that aren t needed as well as radios Using a open flame near a battery can cause battery This will avoid sparks and help save both gas to explode People have been hurt doing this batteries In addition it could save the radio and some have been blinded Use a flashlight if you z ee ae need more light Notice If you leave the communications navigation equipment on they could be badly damaged The Be sure the batteries have enough water You don t repairs will not be covered by the warranty g need to add water to the Delco Freedom battery or batteries installed in every new GM vehicle But if a battery has filler caps be sure the right amount of fluid is there If it is low add water to take care of that first If you do not explosive gas could be present Battery fluid contains acid that can burn you Do not get it on you If you accidentally get it in the eyes or on the skin flush the place with water and get medical help immediately 3 Locate the slave receptacles on both vehicles and Fans or other moving engine parts can injure you unscrew the cover badly Keep your hands away from moving parts once the engine is running Connect the slave cable to the vehicle with the dead battery Connect the slave cable to the vehicle with the good battery 6 Start the vehicle with the good battery 7 Allow the vehicle with the dead battery to charge for 10 minut
12. dry grass or other dry ground cover Switch heater off while refueling vehicle Switch heater off BEFORE entering fueling stations An indicator lamp will illuminate the switch To deactivate the heater move the switch to the OFF position To Prevent Burning NEVER touch hot components of the heating system If the switch is in the ON position and flashing there is a problem with the system Refer to the 2003 LSSV Service Manual Military Supplement The heater is a diesel powered supplementary heating system that will heat the engine coolant of the vehicle This will prevent cold start up of the engine It can be used in conjunction with the factory coolant heater Turn the fuel fired coolant heater OFF when not in use 2 4 Storage Areas Cargo Cover Soft Top If the vehicle is equipped with a soft top cargo cover it must be fully installed and properly anchored before traveling on the highway The side panels and rear panel of the cargo cover can be rolled up The cargo cover allows ventilation within the closed portion through opening vents located on the front of the top Rolling Up the Side Panels 21 Release tension on the j hooks by pushing the release on the front of the hook 12 Remove the plastic hook from the bed fastener 13 Pull apart the velcro flaps on both side panels near the vehicle cab 4 Pull apart the velcro flaps on both side panels near the back of the vehicle 5 Roll the
13. e downs four are provided on each side of the rear cargo area The cargo tie downs A are used to strap cargo in and keep it from moving inside the cargo area Each of these tie down rings are rated for a maximum pull of 660 lbs 300 kg upward or 450 Ibs 200 kg of horizontal force CAUTION Do not load the vehicle any heavier that the Gross Vehicle Weight Rating GVWR or either the maximum front or rear Gross Axle Weight Rating GAWR If you do parts on the vehicle can break and it can change the way the vehicle handles These could cause you to lose control and crash Also overloading can shorten the life of the vehicle Weapons Mount Weapon Mount Floor Mount CAUTION If the weapon is improperly stored it can move around in a collision or sudden stop People in the vehicle could be injured Be sure to secure any such item properly The weapon should be made safe when stored in this mount The floor mount weapon mount is located behind the front seats and will secure two weapons 2 7 Mounting the Weapon 1 Place the stock of the weapon into the lower mount 2 Place the barrel into the upper mount until fully seated in the clamp 3 Secure with strap and pull to tighten Pull the strap outward and slide it over the barrel of the weapon and secure the buckle by pulling tight 2 8 Weapon Mount Cab Mount If the weapon is improperly stored it can move around in a coll
14. es Note It may take up to 30 minutes to charge the battery enough to start depending on its state of charge 8 Start the vehicle with the dead battery 9 Remove the slave cable in the reverse order that it was installed Take care not to let the cable ends touch each other or any other metal 5 10 Vent Filters Rear Axle Vent Tube Filter The rear axle vent tube filter is located on the vent hose that is attached to the top of the axle housing Refer to the Maintenance Schedule to determine how often to inspect the filter and when to change it See Front Rear Axle Inspection Transfer Case Vent Tube Filter The transfer case vent tube filter is located on the vent hose on the driver s side of the transfer case housing Refer to the Maintenance Schedule to determine how often to inspect the filter and when to change it See Transfer Case Inspection Front Axle Vent Tube Filter The front axle vent tube filter is located on the vent hose in the engine compartment near the left inner wheel well Refer to the Maintenance Schedule to determine how often to inspect the filter and when to change it See Front Rear Axle Inspection Replacement Bulbs Lamp Bulb Number Blackout Headlamp Topper Dome Lamp 24 Volt Gage Lamp License Plate Lamp Note The bulbs in the blackout tail stop lamp and front marker lamps are light emitting diodes LED instead of incandescent bulbs They are not replaceable and are servi
15. f the 12 volt battery 12 volt side of the vehicle with the dead battery 5 5 Connect the negative cable to the negative terminal of the 12 volt system of the vehicle with the good battery Do not let the other end touch anything until the next step The other end of the negative cable does not go to the dead battery It goes to a heavy unpainted metal part ofthe engine in the vehicle with the dead battery 6 Connect the positive cable to the positive terminal 12 volt system of the vehicle with the good battery 8 Attach the cable at least 18 in 45 cm away from the dead battery but not near engine parts that move The electrical connection is just as good there but the chance of sparks getting back to the battery is much less 5 6 9 Start the vehicle with the good battery Allow the vehicle s battery to charge for 10 minutes before attempting to start the vehicle Note It may take up to 30 minutes to charge the battery enough to start the vehicle depending on the battery s state of charge 10 Start the vehicle with the dead battery 11 Remove the cables in reverse order to prevent electrical shorting Take care that they do not touch each other or any other metal 12 Volt Positive Dead Battery 12 Volt Positive Good Battery 12 Volt Negative Good Battery Engine Ground Dead Battery VOWS If this procedure does not work you will need to disconnect the 24 volt side ba
16. he engine compartment A 24 Volt Stud on Equalizer B 24 Volt Stud on Equalizer Cover C Fuel Fired Heater D Auxiliary Items 5 14 24 Volt Power Source Battery Equalizer The battery equalizer is located on the left rear wall of the cab The primary function of the battery equalizer is to maintain battery balance or equalization charge in a predominately 24 volt system which requires regulated 12 volt power The battery equalizer can deliver up to 100 amps of continuous 12 volt current for practically any 12 volt or 24 volt load such as two way radios navigations or the 24 volt batteries NOTES NOTES 5 16 Section 6 Maintenance Schedule Maintenance Schedule uueeeers nennen 6 2 Front Rear Axle Inspection nnen 6 2 Transfer Case Inspection een 6 2 Fuel Fired Coolant Heater Inspection 6 3 Winch Inspection eeseesennnnnnnennnn 6 3 Maintenance Schedule Front Rear Axle Inspection Inspect the front rear axle fluid level and add as needed Inspect the constant velocity joints and axle seals for leakage The front and rear axles are equipped with an in line filter on the vent tubes Inspect the filters for blockages and replace as needed See Front Axle Vent Tube Filter and Rear Axle Vent Tube Filter in the Index for further information on the location of the front and rear axle filters Refer to Mai
17. hicle may cause damage The warranty does not cover parts or components that failbecause ofoverloading Do not overload the vehicle Make sure that all cargo is properly secured to prevent the load from shifting All loads must be distributed evenly over the axle and secured Refer to Loading The Vehicle in the Index of the 2003 Vehicle Owner s Manual for more information on vehicle loading Weight of the Trailer Maximum Trailer Weight GCWR Regular Cab Model 12 000 Ibs 5 443 kg 22 000 Ibs 9 980 kg Crew Cab Model 12 000 Ibs 5 443 kg 22 000 Ibs 9 980 kg The Gross Combination Weight Rating GCWR is the total allowable weight of the completely loaded vehicle and trailer including any passengers cargo equipment and conversion The GCWR for the vehicle should not be exceeded Towing capacity is limited by the military hitch not vehicle performance Refer to Towing a Trailer in the Vehicle Owner s Manual for additional information Pintle Hitch A pintle hitch is located at the rear of the vehicle and is removable from the receiver Notice Before operating inspect for proper operation worn damaged or missing parts and secure mountings Correct as required before use Operating the Pintle Hitch 4 10 To Open 1 Open the latch by removing latch pin F 2 Pull up on the lock latch C while lifting the latch D To Close 1 Push the latch D until the lock latch C locks in place 2
18. ill does not work in the lower end of the yellow band this is properly refer to your local GM dealer unacceptable and the battery may be dead 3 8 NOTES 3 9 NOTES 3 10 Section 4_ Driving the Vehicle Your Driving the Road and the Vehicle 4 2 TOWING u 4 8 Using JP8 as a Fuel unerseenserseennnnnnennnnnnnneennnn nenn 4 2 Towing the Vehicle 4 04 4 8 Loading the Vehicle n 4 2 Towing a Trailer 4 8 WIIG EPEE EAE EET TEE 4 3 Loading the Vehicle 4 8 If You Are Stuck In Sand Mud Ice or Snow 4 5 Weight of the Trailer nnn 4 9 Pintle Hitch Trailer Wiring Connector nen 4 11 Trailer Connector Adapter eeee 4 11 4 1 Your Driving the Road and the Vehicle Using JP8 as a Fuel Use of JP8 fuel is acceptable in Duramax 6 6L diesel vehicles and will not impact warranty coverage For additional information on other compatible fuels refer to the 2004 Duramax Diesel Engine Owner s Manual Supplement Loading the Vehicle Do not load the vehicle any heavier than the GVWR or either the maximum front or rear GAWR If you do parts on the vehicle can break or it can change the way the vehicle handles These could cause you to lose control Also overloading can shorten the life of the vehicle Notice The warranty does not cover parts or componen
19. ision or sudden stop People in the vehicle could be injured Be sure to secure any such item properly The weapon should be made safe when stored in this mount Lower Weapon Mount To secure weapons in the vehicle s mount 1 Place the stock into the lower weapon mount Upper Weapon Mount ma y Zn 2 Place the barrel into the upper weapon mount until fully seated Pull the strap outward and slide it over the barrel of the weapon and secure the buckle by pulling tight 2 9 NOTES 2 10 Section 3 Instrument Panel Exterior Lamps ennnennennnnennnn 3 2 Interior Lamps eennenennnnennnnnenn 3 6 Service and Blackout Lighting 3 2 Topper Dome Lamp 20ur240nnennnsnnnsnnnnnnnenn 3 6 Operating Service and Blackout Lighting 3 4 Warning Lights Gages and Indicators 3 8 24 Voll C 0 Seer eee er ee eer eee reer rer ere 3 8 3 1 Exterior Lamps Service and Blackout Lighting BLACKOUT SERVICE DRIVE LIGHT ON LIGHTS ON BLACKOUT SS DY se 2 OF Notice If the vehicle is not going to be driven for 24 hours or more the service lights switch must be placed in the ALL OFF position This will help prevent drain on the batteries Notice Before normal driving operations turn on service lights to ensure headlights brake lights and turn signals are ope
20. itch OFF OFF OFF OFF ON OFF OFF ON OFF Blackout Drive Light Switch ON OFF ON OFF 3 5 Interior Lamps Topper Dome Lamp The fiberglass topper dome lamp is controlled by a master switch on the side of the dome lamp and a pair of 3 way switches With Blackout Lighting The interior 3 way switch A is located on the accessory panel Without Blackout Lighting The interior 3 way switch A is located on the instrument panel I P bezel to the left of the steering column The bed mounted 3 way switch A is located in the left rear of the cargo bed The topper mounted master switch A is located on the rear center of the topper roof If the master switch is turned OFF the following will occur The interior mounted 3 way switch will not function The bed mounted 3 way switch will not function The dome lamp will not function in the blackout mode 3 7 Warning Lights Gages and Indicators 24 Volt Gage The 24 volt gage is located in the accessory panel next to the service and blackout lighting switch Engine Running Reading Engine Off Reading The gage needle should be in the green band when In a no load situation with the engine off the gage engine speed is above an idle If the needle is not in needle should be mid way between the red band and the green band the fuse may have blown If the fuse green band in the yellow band If the gage needle is is not blown and the system st
21. ls You will find a number of safety cautions in this book We use a box and the word CAUTION to tell you about things that could cause personal injury if you were to ignore the warning These mean there is something that could hurt you or other people In the caution area we tell you what the hazard is Then we tell you what to do to help avoid or reduce the hazard Please read these cautions If you don t you or others could be hurt Vehicle Damage Warnings Also in this supplement manual you will find these notices Notice These mean there is something that could damage the vehicle In the notice area we tell you about something that can damage the vehicle Many times this damage would not be covered by the warranty and it could be costly But the notice will tell you what to do to help avoid the damage When you read other manuals you might see CAUTION and NOTICE warnings in different colors or in different words You ll also see warning labels on the vehicle They use the same words CAUTION or NOTICE NOTES Section 1 Seats and Restraints Troop SeatS coococicococicocococococonononoonco nono nonnnon ono n non nonn nao nco rca Restraints noo nonononono cnn cnn nonnnnnnannos 1 3 Folding the Seat Down Rear Safety Sapenni eine 1 3 Folding the Seat Up nenenenn 1 1 Troop Seats When the seat is in the up position the quick release pin will go through the left hand leg f
22. nspection Inspect the wire rope before and after each winching operation If the wire rope has become kinked or frayed the wire rope needs to be replaced Be sure to also inspect the winch hook and hook pin for signs of wear or damage and replace if necessary Inspect the remote control for damage if equipped Refer to the WARN industries operator s manual in the vehicle s glove compartment for additional inspection and maintenance information 6 3 6 4 NOTES Section 7 Customer Assistance Information Customer Assistance Information Contact InformatiON ooocnccccnccconccnncnnconncinnnnonono 7 2 Customer Assistance Information For customer assistance phone numbers refer to Contact Information To assist in our review of your concerns provide the following information The Vehicle Identification Number This will be on the VIN plate in the cab of the vehicle Current mileage on the vehicle Nature of the problem 7 2 Contact Information Telephone Users Department Phone Number GM Customer Assistance Center general information dealer 1 800 222 1020 location other concerns Roadside Assistance Center towing and all Roadside 1 800 243 8872 Assistance program services Online Users You can find specific information on e Service Parts After Sales Assistance GM Military History News Events Refer to the web for updated information www gm defense com Ap
23. ntenance Schedule in the Index of the 2003 Vehicle Owner s Manual for additional maintenance information on the vehicle Transfer Case Inspection Inspect the transfer case fluid level and add lubricant if necessary On manual shift transfer case oil the control lever pivot point and all exposed control linkage The transfer case is equipped with an in line filter on the vent tube Inspect the filter for blockages and replace as needed Inspect vent hose at the transfer case for kinks and proper installation See Transfer Case Vent Tube Filter in the Index for further information on the location of the filter Refer to Maintenance Schedule in the Index of the 2003 Vehicle Owner s Manual for additional maintenance information on the vehicle Fuel Fired Coolant Heater Inspection The heater requires no periodic maintenance other than a visual inspection by a qualified technician preferably prior to cold weather use The technician can ensure that the heater and all components are free from damage and in proper working condition During the warmer months of the year when heating is not required the heater should be switched ON and allowed to run for 5 to 10 minutes once a month at a minimum This will keep a clean fresh supply of fuel in the heater fuel system and keep all moving parts in top operating condition For troubleshooting information refer to the 2003 LSSV Military Trucks Service Manual Supplement Winch I
24. nual will assist you in the proper use and maintenance of the vehicle The sections in this supplement correspond to the sections in the 2003 Vehicle Owner s Manual and the 2003 Duramax Diesel Engine Owner s Manual Supplement Please keep this supplement with the owner s manual and diesel supplement in the vehicle so it will be there if you ever need it while you re on the road Litho in USA Part No LSSVOMO3 First Edition ii This manual includes the latest information at the time it was printed We reserve the right to make changes in the product after that time without notice How to Use This Manual Many people read the owner s manual from beginning to end when they first receive the vehicle If you do this it will help you learn about the features and controls for the vehicle In this manual you ll find that pictures and words work together to explain things Copyright General Motors Corporation 10 01 04 All Rights Reserved Index A good place to look for what you need is the Index in back of the manual It s an alphabetical list of what s in the manual and the page number where you ll find it Driving the Vehicle As with other vehicles of this type failure to operate this vehicle correctly may result in loss of control or an accident Refer to The Driving the Road and the Vehicle and Off Road Driving with The Four Wheel Drive Vehicle in the 2003 Vehicle Owner s Manual Safety Warnings and Symbo
25. or abrasives All cleaning agents should be flushed promptly and not allowed to dry on the surface Do not towel dry or wax the surface The windows should be washed with a water soaked cloth Do not rub dry Vehicle Information Shipping Data Plate K25903HD SHIPPING DATA PLATE 2071 0 m 1935 0 L I ER 1083 2086 por zes 7a VOLUME IHX W X LI 23 4m The data plate is used to inform the operator of the vehicle as to the make model Gross Vehicle Weight GVW and vehicle dimensions It is located on the left corner of the left front inner door panel Government Vehicle Data Plate U S PROPERTY NOMENCLATURE TRUCK LSSV MCTL MAKE AND MODEL CHEV2500HDCK25903 MFRS VIN 1GCHK24133E321226 REGISTRATION NO N A CURB WEIGHT MAX PAYLOAD GVWR GCWR 6860 LBS 2340 LBS 9200 LBS 22000 LBS DATE OF DELIVERY 10 08 03 WARRANTY 36 MONTHS 36 000 MILES CONTRACT NO GS 3QF K0002 RPNNL5086 PART NO TX181623 The data plate is used to inform the operator of the vehicle as to the upfitting information and other specifications It is located on the left front corner of the inner door panel 5 13 Electrical System Fuses and Circuit Breakers Circuit breakers protect the power accessories When the current load is too heavy the circuit breaker opens protecting the circuit until the problem is fixed 24 Volt Circuit Breakers These circuit breakers are on the left rear fender support bracket of t
26. or passenger s side If the vehicle is equipped with troop seats this feature seats or a right hand leg for driver s side seats It will provides space for up to eight passengers in the cargo then go through the seat channel and will be placed in area of the pickup model The seats can be lowered front of the hinge pin individually for use or raised for storage The seats lock in both the up and down positions Folding the Seat Down Troop Seat Operation u 1 Remove the pin and place the legs into the joint of the cargo area side and the floor A quick release pin is located on the left or right side of the troop seat leg immediately under the hinge pin 1 2 2 Place the pin in the hole provided under the hinge pin The seat is now locked in the down position Folding the Seat Up Reverse Steps 1 and 2 To remove the troop seats refer to Seats in the 2003 LSSV Military Trucks service manual supplement Restraints Rear Safety De Strap Whenever the troop seats are occupied the safety strap should be attached across the top of the rear seat backs using the eye bolts provided 1 3 NOTES Section 2_ Features and Controls WINDOWS aaa 2 2 Storage Areas ioscan dansk rd 2 5 Rear Topper Window uensnensnsennnennennn 2 2 Cargo Cover Soft Top cccccecccceseeeseceteseeeeeneeeeees 2 5 Side Topper Window een 2 2 Rolling Up the Side Panels un 2 5 Sliding Rea
27. pearance Ca re n u nn en een 5 12 Cleaning the Outside of the Vehicle 5 12 Cleaning the Soft Top Cargo Cover 5 12 B Blackout Drive Light Control rennen 3 3 Cargo Cover Soft TOP unessessnnesnennnnennnnnennennnnnnne nennen 2 5 Cardo Tie DOWNS ciar 2 7 Changing ai Flat Feien 5 11 Cleaning the Outside of the Vehicle 5 12 Cleaning the Soft Top Cargo Cover 5 12 Customer Assistance Information ee 7 2 Contact NOA ON a 7 2 D Driving he Vehicle aia iii Elecinical SyStem icc iis Alacra eee de eee 5 14 Fuses and Circuit Breakers u een 5 14 24 Volt Circuit Breakers 5 14 24 Volt Power Source 5 14 Exterior LaMPS3 cunda 3 2 Service and Blackout Lighting eeee 3 2 Service Lights Blackout ContrOl ooninonnncnnnnincononcc 3 2 Blackout Drive Light Controls 3 3 Operating Service and Blackout Lighting 3 4 E Folding the Seats DOWN sesigege iaie 1 2 Folding the Seats Up une 1 3 Front Axle Vent Tube Filter ernennen nenn 5 10 Front Clevis Towing Provisions ursmsernneeseen nenn 4 6 Front Rear Axle Inspection enenn 6 2 Fuel Fired Coolant Heater 2 4 Fuel Fired Coolant Heater Operation 2 4 Fuses and Circuit Breakers 5 14 Fuel Fired Coolant Heater Inspection
28. r Window 2 3 Storing the Cargo Cover uunessensersesnnnennnnnennennnnen nenn 2 5 Starting and Operating the Vehicle 2 3 Cargo Tie Downs 0 2 7 Starting The Engine nee 2 3 Weapons Mount 2 222422244224200200nnnnnnnennnnnnnenenneennnn 2 7 Fuel Fired Coolant Heater 2 4 Weapons Mount Floor Mount 2 7 Fuel Fired Coolant Heater Operation 2 4 Weapons Mount Cab Moun cceeeeeeeeeees 2 8 2 1 Windows If the vehicle is equipped with a topper it features tempered opening windows that have locking handles Rear Topper Window Opening the Rear Window Door 1 Turn both handles A clockwise 90 2 Pull open the rear window door A cylinder on both sides of the window will assist with opening and hold the window in the open position Closing Rear Window Door 1 Pull the window door down 2 Turn both handles A counter clockwise 90 2 2 Notice The window must be fully closed before operation ofthe vehicle Side Topper Window Open the Side Window Doors 1 Turn both handles A clockwise 90 2 Pull open the window door A cylinder on both sides of the window will assist with opening and hold the window in the open position Closing the Side Window Doors 1 Pull the window door down 2 Turn both handles A counter clockwise 90 Notice The window must be f
29. rational 3 2 Service Lights Blackout Control The switch located on the accessory panel next to the 24 volt gage is the service lights blackout control With the Ignition Switch in the ON Position Pull the switch outward then push upward to the service ON position All normal service lamps will be operational with normal controls Move the service lights blackout switch to the center ALL OFF position All lamps and accessory power to the vehicle will turn off Move the switch to the blackout position the following will occur e The blackout lighting system will be operative e The front and rear blackout marker lamps will illuminate e The blackout stop lamps will illuminate when the brakes are applied The instrument panel warning lights will remain functional automatically after you release it from either the ON or OFF position e The hazard lights will remain functional e The horn will not be functional The vehicle s military 12 pin trailer wiring connector and trailer lamps are also controlled by this switch Blackout Drive Light Control The switch located on the accessory panel next to the service light switch is the blackout drive light control The service lights blackout control switch must be in blackout position or in the down position for the blackout drive lights to function With the ignition switch in the ON position Pull the switch outward then up to the ON position
30. rt you They can be dangerous because They contain acid that can burn you They contain gas that can explode or ignite They contain enough electricity to burn you If you do not follow these steps exactly some or all of these things can hurt you Notice Ignoring these steps could result in costly damage to the vehicle that would not be covered by the vehicle warranty Trying to start the vehicle by pushing or pulling it will not work and it could damage the vehicle 5 3 This procedure applies only to the 12 volt battery located Notice If you leave the communications navigation on the passenger s side of the vehicle equipment on there is a risk that they could be badly damaged The repairs would not be covered by the 1 Get the vehicles close enough so that jumper warranty cables can reach but be sure the vehicles are not touching each other If they are it could cause a ground causing the vehicle not to start The bad grounding could damage the electrical systems 3 Ensure the jumper cables do not have loose or missing insulation If they do you could get shocked and the vehicle could be damaged Before you connect the cables here are some basic things you should know Positive will go to positive Negative will go to a heavy unpainted metal engine part or a remote negative terminal if the vehicle has one To avoid the possibility of the vehicles rolling set the parking brake firmly on
31. sides upward 6 When the sides reach the top they can be held in place by inserting the cargo cover straps in the clips at the top of the cargo cover Storing the Cargo Cover 1 Release tension on the hooks by pushing the release on the front of the hook Remove the plastic hook from the bed fastener Pull apart the velcro flaps on both side panels near the vehicle cab Pull apart the velcro flaps on both panels near the back of the vehicle Release the six cover straps located inside the cargo box that attaches the cover to the cargo cover bows Remove the cover from the cargo cover bows Fold the cover neatly and store it behind the seat in the truck cab 2 5 10 Stack the bows on top of each other without 8 Release the four corner striking the cab or the troop seats if equipped support straps push down equally on both sides of the upper part of the front and rear bows 11 Pull upward equally on both sides of the upper part of the center bow 12 Standing at the rear of the vehicle push the bows forward 13 Secure the bows in place with the front support straps 14 To reinstall the cargo cover reverse Steps 1 13 9 Remove the six quick release pins from the sides of Note The cargo cover is marked with the word FRONT the cargo cover bows on the inside top to aid in proper positioning of the cover onto the vehicle 2 6 Cargo Tie Downs If the vehicle is equipped with cargo ti
32. teral Rear 5 500 Ibs 2 494 kg 4 7 Towing Towing The Vehicle When towing the vehicle you should always use a properly equipped wrecker recovery vehicle Refer to Towing Your Vehicle and Recreational Vehicle Towing in the Index of the 2003 Vehicle Owner s Manual for further information on towing the vehicle Notice The steering wheel must be secured properly with the appropriate wheel locking device to keep the wheel in the straight position The vehicle transfer case must be in NEUTRAL N Towinga Trailer The vehicle is equipped for towing a trailer Notice Do not exceed the maximum allowable weight the vehicle is designed to carry Exceeding the maximum allowable weight may cause damage to the vehicle Refer to Towing a Trailer in the Index of the 2003 Vehicle Owner s Manual for more information on trailer towing 4 8 The vehicle is equipped with a pintle hitch for towing a trailer You must not exceed the maximum trailer weight towing capacity for that vehicle Refer to the chart on the following page to find the maximum trailer weight for the vehicle Loading The Vehicle AN CAUTION Do not load the vehicle any heavier than the GVWR or either the maximum front or rear GAWR If you do parts on the vehicle can break or it can change the way the vehicle handles These could cause you to lose control Also overloading can shorten the life of the vehicle Notice Overloading the ve
33. the front blackout drive lamp will activate Pull the switch outward then down to the OFF position the blackout drive lamp will deactivate The switch will return to the center position Operating Service and Blackout Lighting Exterior Lamp or Device Service Lights Blackout Switch Blackout Drive Light Switch Headlamps and Taillamps SERVICE ON OFF Parking Lamps SERVICE ON OFF Front Rear Side Marker Lamps SERVICE ON OFF Marker Lamps Roof Fender and End Gate SERVICE ON OFF Stop Lamps SERVICE ON OFF Back Up Lamps SERVICE ON OFF License Plate Lamps SERVICE ON OFF Front Rear Turn Signals SERVICE ON OFF Hazard Warning Lamps SERVICE ON ON OFF Cargo Lamp If Equipped SERVICE ON OFF Horn SERVICE ON OFF Front Rear Blackout Marker Lamps BLACKOUT ON OFF Blackout Stop Lamps BLACKOUT ON OFF Blackout Drive Lamp Headlamp BLACKOUT ON Exterior Lamp or Device Instrument Panel Switch Illumination Radio Clock Illumination Headlamp High Beam Indicator Turn Signal Hazard Warning Indicators Four Wheel Drive Indicator Dome Courtesy Lamps Glove Compartment Lamp Warning Chime Headlamps On Instrument Cluster Warning Lights Mechanical Device Automatic Transmission Shift lock Control Torque Converter Lockup Clutch SERVICE SERVICE SERVICE SERVICE SERVICE SERVICE SERVICE Service Lights Blackout Switch ON ON ON ON ON ON ON SERVICE ON Service Lights Blackout Switch SERVICE ON SERVICE ON Blackout Drive Light Sw
34. the hand held remote control to allow the operator to stand clear while controlling the winching process The remote control provides control of the forward or reverse rotation of the spooling drum The winch will only work with the remote How the Winch Reacts to Load The winch is rated at maximum pulling capacity This occurs on the first layer of wire rope on the drum As the layers increase the pulling power decreases Exceeding the winch capacity could cause the winch to fail or the wire rope to break Winch Accessory Kit The Winch Accessory Kit Contains the Following Items Tow Hooks Secured properly to the vehicle s frame tow hooks provide an attachment point for wire rope straps and chains e Clevis D Shackles The D Shackle is a safe means for connecting the looped ends of cables straps and snatch blocks e Snatch Block Used properly the multi purpose 24 000 Ibs 10 886 kgs snatch block allows you to do the following e Increase the winch s pulling power e Change the pulling direction without damaging the wire rope e Choker Chain Can be used to hook up to another vehicle or sharp objects for an anchor point e Gloves Wire rope through use will develop barbs which can slice skin e Recovery Straps Used to snatch or pull out a stuck vehicle e Tree Truck Protector Use this with a clevis D shackle to secure the wire rope to an anchor point If You Are Stuck In Sand Mud I
35. ts that fail because of overloading 4 2 Make sure that all cargo is properly secured to prevent the load from shifting All loads must be distributed evenly over the axle and secured to the tie down rings provided Refer to Loading Your Vehicle in the Index of the 2003 Vehicle Owner s Manual for more information on vehicle loading If the vehicle is equipped with troop seats you can carry up to eight passengers Passengers must stay seated at all times and the rear safety strap in place Winch Multi Mount The multi mount winch has 9 000 Ibs 4 082 kg of single line pull The multi mount slides into the hitch receiver and allows you to move and operate the winch from the front or the back of vehicle Refer to WARN industries operator s manual in the vehicle glove compartment for additional instructions and warnings Multi Mount Winch Storage The multi mount winch is stored in a locking storage box located in the upper middle of the cargo area The winch is secured in the box by four floor mounted eye bolts 4 3 Permanent Mount 7i 7 ZN Y ANZ LY Li l op WM ul 7 mum 7 a ar l The winch is electrically powered from the vehicle batteries The permanent mount winch has 12 000 Ibs 5 440 kg of single line pull Refer to WARN industries operator s manual in the vehicle glove compartment for additional instructions and warnings 4 4 Control of the Winch The winch is controlled by
36. ttery and charge it alone for 10 minutes Replace the battery and repeat the jump starting procedures as outlined Note This procedure should only be performed by authorized personnel 5 7 Slave Starting Batteries can hurt you They can be dangerous because They contain acid that can burn you They contain gas that can explode or ignite They contain enough electricity to burn you If you do not follow these steps exactly some or all of these things can hurt you Notice Ignoring these steps could result in costly damage to the vehicle that wouldn t be covered by the vehicle warranty Trying to start the vehicle by pushing or pulling it will not work and it could damage the vehicle 5 8 You should only use the NATO slave receptacle and slave cable when performing this operation 1 Get the vehicles close enough so that the slave cable can reach but be sure the vehicles are not touching each other If they are it could cause a ground connection causing the vehicle not to start and the bad grounding could damage the electrical systems To avoid the possibility of the vehicles rolling set the parking brake firmly on both vehicles involved in the jump start procedure Put the automatic transmission in PARK P Be sure the transfer case is in a drive gear and is NOT in NEUTRAL N 2 Turn off the ignition on both vehicles Unplug unnecessary accessories plugged into the IN CAUTION cigarette lighter or ac
37. ully closed before operation of the vehicle Sliding Rear Window If the vehicle is equipped with a sliding rear window it features tempered glass surrounded by a durable black finish aluminum frame and three panel design Locking latch adds cab security To open the window hold the latch in the open position and slide the window open To close the window slide the window until the latch is fully engaged against the frame Lo Starting and Operating the Vehicle Starting the Engine The diesel engine starts differently than a gasoline engine ZN CAUTION Do not use gasoline or starting aids such as ether in the air intake They could damage the engine There could also be a fire which could cause serious personal injury Refer to the 2004 Duramax Diesel Engine Owner s Manual Supplement located in the glove compartment 2 3 Fuel Fired Coolant Heater Fuel Fired Coolant Heater Operation To Prevent Asphyxiation DO NOT operate while in confined spaces such as closed unventilated enclosures Open an outside enclosure door before operating the heater The fuel fired coolant heater is controlled by a toggle switch located on the instrument panel I P bezel to the left of the steering column The heater is activated by moving the switch A to the ON position To Prevent Fire DO NOT operate heater where flammable or explosive materials gases or dusts may be present DO NOT operate heater over
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