5
7. SERVICE
Procedure for replacing an inoperative actuator:
1. If the deck is lowered, or can be lowered, skip to step 6. If the deck is raised and stuck, complete steps 2
through 5 before proceeding.
2. If the deck is loaded, remove the load if possible.
3. Place jack stands or blocks under the top deck to support it in the raised position while preparing it to be
lowered.
4. If necessary, use a jack or forklift to lift the top deck slightly, to free the actuators and actuator pivot bolts.
5. Disconnect the inoperative actuator(s) from the control wiring harness. Unfasten the inoperative actuator(s)
from the torsion arm weldment and the actuator mount.
6. Check that no persons or objects are on the lower deck, or in the cargo area, then remove the supports and
carefully lower the top deck. If one actuator is still functioning and connected, lower the top deck using the
normal operating procedure.
NOTE:
One actuator is sufficient to safely lower the top deck, but does not
have the capacity to raise the top deck while loaded.
If both actuators were non-functioning and disconnected, use a jack or forklift to carefully lower the top
deck onto wood blocks placed on top of the lower deck. The top deck should be held 1-2 in. above the
lower deck.
7. Extend the replacement actuator(s) with an auxiliary 12 volt source, and fit the new actuator(s) to the actua-
tor mount and torsion arm.
8. Connect the new actuator(s) to the control wiring harness. Ensure that all persons are clear of the cargo
area, and test the operation of the deck through several cycles.
Procedure for clearing blockages in the DD-2000:
1. If the deck is loaded, remove the loads, and lower the top deck, if possible.
2. If the top deck is in the raised position, place jack stands under the top deck for support.
3. Remove the blockage, working from above the upper deck or from the side door, if possible.
4. Inspect the decks, frame, and mechanism for damage.
5. Ensure that all persons are clear of the cargo area, and remove the jack stands.
6. Test the operation of the deck through several cycles.
Park the vehicle in a level, flat area, and apply the parking brake before performing any maintenance.
Turn the
“System Lock”
key switch to the “Off” position and remove the key before performing any
maintenance.
Perform maintenance work from outside the deck, whenever possible.
CAUTION
The top deck will be free to move if both actuators are disconnected from the torsion arm, and
Will Fall if
Unsupported.
Do NOT force out the actuator pivot bolts. If the pivot bolts are difficult to remove they may still be support-
ing the top deck. When the load is removed from the actuators the pivot bolts will be easy to remove.
WARNING
Park the vehicle in a level, flat area, and apply the parking brake before performing any maintenance.
Turn the
“System Lock”
key switch to the “Off” position and remove the key before performing any
maintenance.
Perform maintenance work from outside the deck, whenever possible.
CAUTION