Link DD2000-XLC Manual

Link Mfg. Ltd.
223 15th St. N.E.
Sioux Center, IA USA
51250-2120
www.linkmfg.com
QUESTIONS?
CALL CUSTOMER
SERVICE
1-800-222-6283
OPERATION &
MAINTENANCE
MANUAL
DD2000-XLC
7226A000
72262112
JAN 24, 2023

2
1. INTRODUCTION
Thank you for choosing a Link Cargo Management
Products (CMP) DD2000-XLC Double Deck
system. We want to help you to get the best results
from the deck and to operate it safely. This manual
contains information to introduce you to the Link
CMP DD2000-XLC and to assist you with its
operation. The manual is intended solely for use
with this product.
All information in this manual is based on the latest
information available at the time of printing. Link
Manufacturing reserves the right to change its
products or manuals at any time without notice.
Contact Link CMP at [phone] for
information on recent changes to products.
Damaged components should be returned to Link
with a pre-arranged Returned Goods Authorization
(RGA) number through the Customer Service
Department. The damaged component may then
be replaced if in compliance with warranty
conditions.
2. SAFETY SYMBOLS, TORQUE SYMBOL, and
NOTES
IMPORTANT: IT IS IMPORTANT THAT THE EN-
TIRE OPERATION INSTRUCTIONS BE READ
THOROUGHLY BEFORE USING THIS SYSTEM.
This is the safety alert
symbol. It is used to alert
you to potential personal
injury hazards. Obey all
safety messages that follow
this symbol to avoid possible
injury or death.
WARNING
WARNING indicates a
potentially hazardous
situation which, if not
avoided, could result in death
or serious injury.
CAUTION
CAUTION indicates a
potentially hazardous
situation which, if not
avoided, could result in
minor or moderate injury.
The torque symbol alerts you
to tighten fasteners to a
specified torque value.
3. SAFE WORKING PRACTICES:
3.1
3.2
4. OPERATION GUIDELINES
4.1 In order for this deck to operate properly, it must
operate in the parameters specified by Link.
4.2 No alterations of any Link deck component is
permitted without proper authorization from
qualified Link personnel.
Link products must be installed by a trained technician
when being placed into an Electric Vehicle (EV). Electric
Vehicles have higher voltage batteries and cables, and
drilling into Electric Vehicles may cause serious bodily
harm and possible death.
Note: Link is not responsible for optional configurations
or equipment that restrict the installation of the product
in any way. Consult OEM body builder guides for addi-
tional installation guidelines.
WARNING
 Practice safe lifting procedures.
 The deck weldments are heavy, and can cause in-
jury if lifted improperly or dropped. Consider size,
shape, and weight of objects being moved.
 Obtain help or the assistance of a crane when lifting
heavy assemblies. Make certain the path of travel is
clear.
CAUTION

3
5. OPERATION
5.1 Top Deck Controls & Operation
Immediately inside the rear doors against
one of the side walls is the top deck con-
trol box.
There are three items on the control box:
 System Lock On/Off switch (with
key)
 Top Deck Raise / Lower Rocker
Switch
 Circuit Breaker Reset Button
Operation:
 To operate the deck, turn the
power key to the “ON” position.
 Push the rocker switch to
“RAISE” to raise the deck.
 To lower the top deck, push the
rocker switch to “LOWER”.
 Turn the power switch to the “OFF” position
and remove the key when you are finished
operating the deck.
5.2 Loading / Unloading Procedure
1. With the vehicle in park and the parking brake
secured, open the rear door of the vehicle.
2. Fold down the rear ramp.
3. If the top deck is to be used and is in the up posi-
tion, lower the top deck by following the proce-
dures outlined in Step 5.1 of this manual.
4. Slide the items to be transported on to the top
deck, taking care to evenly distribute the load as
best as possible. Secure items with the bier pins
(if caskets) or by placing the legs in the cups
(hospital cots).
5. Raise the top deck and place items to be trans-
ported on the bottom deck, taking care to proper-
ly secure the load.
6. Turn the System Lock On/Off Switch to “OFF”
and remove the key.
7. Move the Deck Latch into supporting position.
8. Raise the rear ramp.
9. Close the rear doors.
10. Reverse the procedure for unloading.
POWER
SWITCH
CIRCUIT
BREAKER
RESET
RAISE
LOWER
ROCKER
SWITCH
 Make certain the vehicle is in park and the park-
ing brake is engaged before loading / unloading
the vehicle.
 Vehicle movement during loading / unloading
could cause operator injury or death.
WARNING
 The capacity of the top deck is 600 pounds
maximum, evenly distributed.
 Loading beyond the capacity may result in
equipment damage or failure that may result in
injury or death.
WARNING
 The System Lock On/Off key switch should be
turned to off and the key removed if the unit is
left unattended to prevent unauthorized use.
CAUTION
 Make certain that the load is properly secured by
properly tightening the bier pin(s).
 Caskets placed on both the top and bottom deck
are prevented from lateral movement by the fric-
tion of the front bumpers combined with the
clamping force of the bier pin.
CAUTION
 Make certain that the deck latch is in the stowed
position before lowering or raising the deck
CAUTION

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6. MAINTENANCE
The DD2000-XLC is designed to last for many years without any major maintenance. Periodically, check
the following items:
Each Time the System is Used:
 Listen for unusual noises and watch to ensure proper movement of the system. If there is a prob-
lem, correct it before continuing to use the system.
Annually:
 Check tightness of all fasteners. (Refer to Torque Table below)
 Visually inspect for cracks or damage at all pivots on the framework and torsion bar and replace piv-
ot bushings or pins if necessary.
 Grease deck-latch pin if necessary
 Check for cracks in the framework and decks and repair or replace if necessary.
 Verify that the electrical control system functions as intended.
FASTENER TORQUE
3/8-UNC NUTS 30-40 FT-LBS
7/16-UNC NUTS 50-60 FT -LBS
1/2-UNC NUTS 80-100 FT-LBS
TORQUE TABLE
5/16-UNC NUTS 15-25 FT-LBS
1/4-UNC NUTS 6-8 FT-LBS
 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
 Perform these checks with the Upper Deck lowered.
CAUTION

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-XLC:
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

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DD-2000-XLC Electrical Troubleshooting Diagram
**Replacement fuses are standard blade type fuses and can be found at your local automotive parts store.
Unit does not operate.
“System Lock” key is in “On” position.
Turn “System Lock” to “On” position.
NO
YES Check
breaker in control box.
TRIPPED
Reset Breaker
OK Check fuse
under hood.
BLOWN
Replace Fuse (30 amp)
OK Check for volt-
age to red wire in control box.
OK
Repair wiring between battery and control box.
NO VOLTAGE
Check for voltage at actuator connectors when Control Switch is operated. Check for opposite voltage when Control Switch is operated in other direction.
OK
Actuator clutches.
NO
ONE CLUTCHES, ONE IS QUIET
Repair wiring in control box or between control box and actuators.
NO VOLTAGE
Actuators are making noise. YES
NO
Actuator buzzes or grinds.
Replace actuator.
YES
BOTH CLUTCH
Determine which actuator operates in reverse, or does not move.
Check that voltage at the actuator connectors is the same polarity.
POLARITY IS OPPOSITE
POLARITY IS SAME
DOES NOT MOVE
Reverse Actuator wiring.
RUNS IN REVERSE

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DD2000-XLC ASSEMBLY
PN: 7226A000

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ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
1 1/4 X 1 1/4 UNC HEX CAP SCR 1 30 PIN-BIER, ADJUSTABLE 2
2 3/8 X 1 UNC HEX CAP SCR 4 31 BIER PIN HOLDER 1
3 3/8 X 2 1/2 UNC HEX CAP SCR 2 32 TUBE-MOUNT, RAMP 1
4 3/8 X 3 1/4 UNC HEX CAP SCR 12 33 WASHER-FLOOR SUPPORT 4
5 7/16 X 1 1/2 UNC HEX CAP SCR 4 34 TUBE-MOUNT, RAMP 1
6 1/2 X 2 1/2 UNC HEX CAP SCR 4 35 BRACKET-STOP, RAMP 1
7 1/2 X 3 1/2 UNC HEX CAP SCR 2 36 HOLDER-GLOVE BOX 1
8 1/2 X 4 UNC HEX CAP SCR 2 37 TIE ROD WELDMENT 2
9 SHSCS-.500X3.250 4 38 ASSEMBLY-CONTROL BOX, DD2000 1
10 1/2 UNF HEX JAM NUT 2 39 BUSHING-PIVOT 2
11 1/2 UNF HEX JAM NUT LH THREADS 2 40 PIN-PIVOT 2
12 1/2 UNC HEX CTR LOCK NUT 10 41 PIN-PIVOT 4
13 1/4 UNC HEX NYLOCK NUT 8 42 BRACKET-MOUNT, ACTUATOR OUTSIDE
DRIVER 1
14 3/8 UNC SERRATED FLANGE NUT 18 43 BRACKET-MOUNT, ACTUATOR OUTSIDE
PASS. 1
15 3/8 UNC TOP LOCK FL NUT 4 44 BRACKET-MOUNT, ACTUATOR INSIDE DRIV-
ER 1
16 7/16 UNC SERRATED FLANGE NUT 4 45 BRACKET-MOUNT, ACTUATOR INSIDE PASS. 1
17 NUT 1/4-20 X 7/16 HT PROPELLER TEE 4 46 WELDMENT-BAR, TORSION 1
18 1/2 TYPE A PLAIN WASHER 4 47 WELDMENT-FRAME, LEFT 1
19 RAMP HOLDER, MALE END 1 48 WELDMENT-FRAME, RIGHT 1
20 CLIP-LATCHING 10 49 WELDMENT-CROSSMEMBER 1
21 DECAL-PINCH POINT 7 50 SWING-ARM, REAR 1
22 BUSHING-PIVOT, NYLON 12 51 SWING-ARM, REAR 1
23 BUSHING-PIVOT, NYLON, 3/8 4 52 DECK-TOP 1
24 ROD END-SPHERICAL, LEFT HAND 2 53 DECK-BOTTOM 1
25 ROD END-SPHERICAL, RIGHT HAND 2 54 LATCH-KIT, DD2000 1
26 ACTUATOR, 12V, 300MM STROKE, 6800N 2 55 1/2 X 1 UNC SOCKET BUTTON HD CAP SCR 2
27 HARNESS-ACTUATOR 1 56 1/2 X 2 3/4 UNC SOCKET BUTTON HD CAP
SCR 2
28 #6 X 1 DRYWALL SCREW W/ DRILL POINT 3 57 1/4 X 1/2 UNC TRUSS HD PH MACH SCR 2
29 1/4-20 X 3/4 BUTTON HD CAP SCREW 5 58 1/4 X 1 1/4 UNC TRUSS HD PH MACH SCR 4

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ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
1 1/4-20 X 7/16 SLAB BASE WELD NUT 24 11 SHEET-DECK 1 2 LABEL-WARNING, DOUBLE DECK 1 12 BOARD-DECK 1 3 #10 X 1 SS FLAT HD TYPE B TAP SCR 16 13 FRAME-DECK, BOTTOM 1 4 1/4 UNC HEX THIN NYLOCK NUT 4 14 RECESSED COT CUP 2 5 1/4 X 5/8 FLANGE HEAD BOLT 4 15 SUPER SIZED RECESSED COT CUP 1 6 1/4 X 3/4 FLANGE HEAD BOLT 20 16 1/4 X 3/4 UNC TRUSS HD PH MACH SCR, SS 4 7 BIER PIN PLATE 2 17 8-32 X 1 OVAL HD MACH SCR-SS 8 8 CR60 CASKET ROLLER 4 18 8-32 X 1 1/4 OVAL HD MACH SCR-SS 16 9 BUMPER-RECESSED, 1.50 O.D. X .63 H 4 19 8-32 UNC HEX NYLOCK NUT, GR B, ZINC PLT 24
10 GLIDE STRIP 4 20 #10 SAE PLAIN WASHER 24
BOTTOM DECK ASSEMBLY

LINK MANUFACTURING, LTD.
223 15TH ST. NE, SIOUX CENTER, IA 51250
1-800-222-6283 www.linkmfg.com
TOP DECK ASSEMBLY
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
1 1/4 UNC HEX NYLOCK NUT (GR B) 22 16 BRACKET-IMPACT, FRONT 1 2 1/4-20 X 7/16 SLAB BASE WELD NUT 32 17 BOARD-DECK 1 3 1/4-20 X 3/4 SOCKET BUTTON HD SS CAP SCREW 8 18 BRACKET-PIVOT, TOP 2 4 #10 X 1 SS FLAT HD TYPE B TAP SCR 16 19 FRAME-DECK, TOP 1 5 1/4-20 X 1/4 SLAB BASE WELD NUT 4 20 BRACKET-PIVOT, TOP 1 6 1/4-20 X 5/8 SOCKET BUTTON HD CAP SCREW 8 21 RECESSED COT CUP 2 7 1/4 UNC HEX THIN NYLOCK NUT 8 22 SUPER SIZED RECESSED COT CUP 1 8 1/4 X 5/8 FLANGE HEAD BOLT 4 23 1/4 X 1/2 UNC TRUSS HD PH MACH SCR, SS 4 9 1/4 X 3/4 FLANGE HEAD BOLT 28 24 1/4 X 3/4 UNC TRUSS HD PH MACH SCR, SS 10
10 BIER PIN PLATE 2 25 1/4 X 1 1/4 UNC TRUSS HD PH MACH SCR, SS 4 11 CR60 CASKET ROLLER 4 26 8-32 X 1 OVAL HD MACH SCR-SS 8 12 BUMPER-RECESSED, 1.50 O.D. X .63 H 4 27 8-32 X 1 1/4 OVAL HD MACH SCR-SS 16 13 GLIDE STRIP 4 28 8-32 UNC HEX NYLOCK NUT, GR B, ZINC PLT 24 14 SHEET-DECK 1 29 #10 SAE PLAIN WASHER 24 15 GUARD-ANGLE, REAR 1 - - -