The HappiJac® Bed Lift System is a chain-driven, two-trolley lift mechanism designed for installation in most toy hauler trailers. It operates on a 12V DC motor and can accommodate one or two beds, or a combination of a bed and a dinette/sofa configuration.
Function Description:
The primary function of the HappiJac Bed Lift System is to raise and lower beds or dinette/sofa configurations within a toy hauler trailer, optimizing space utilization. The system consists of a frame with four vertical c-channel rails, each encasing a chain drive and trolleys. These trolleys have attached brackets that travel between upper and lower limit switches, defining the maximum travel range of the bed(s). An electric brake secures the bed(s) in position once the control switch is released.
Important Technical Specifications:
- Voltage: 12V DC
- Nominal Current Draw:
- 8 amps (1 bed going up)
- 12 amps (2 beds or 1 bed and 1 sofa/dinette configuration going up)
- Load Limit:
- 450 pounds dynamic (moving) load
- 600 pounds static (stationary) load
- Components:
- Frame: Four vertical c-channel rails.
- Trolleys: Upper and lower trolleys that travel within the c-channels. The upper bunk trolley is free-floating and carried by the lower trolley, with its stop height adjustable via "stop blocks."
- Brackets: Screw-in tab brackets are affixed to the upper and/or lower trolleys. Slotted lower trolleys can be fitted with hooked tab brackets for a lower bed platform or hooked brackets with movable arms for a sofa/dinette configuration.
- Limit Switches: Located behind the C-channel, secured by two small screws. These stop the bed(s) at their maximum travel range.
- Control Switch: Operates the upper and lower trolleys, moving them upward or downward.
- Motor: 12V DC motor, chain-driven.
- Brake: Electric brake to secure the bed(s) in position.
Usage Features:
- Control: Operated via a simple UP/DOWN control switch.
- Bed Configurations: Supports single or double bed setups, or a bed with a sofa/dinette.
- Sofa/Dinette Configuration: For sofa/dinette setups, the sofas should be run to the lower limit switch stop, and sofa support legs extended before use. A CAUTION warns against sofa support legs contacting the floor before the bed lift reaches its lower travel limit. A WARNING emphasizes never sitting on or using sofas without support legs extended to prevent personal injury or damage.
- Upper Bunk Lock-Up System (Optional): This mechanism allows the upper bunk trolleys to be locked in an elevated position while the lower trolleys are lowered. To lock, rotate seatbacks to horizontal (if applicable), flip the locking mechanism tab outside the C-channel, press UP until the upper bunk is in the full up position and the locking mechanism engages (audible click), then press DOWN to lower the lower trolleys. To release, flip the locking tab inside the C-channel, press UP until the lower trolley disengages the upper bunk, then press DOWN to bring both bunks down.
- Bunk Pins: Upper trolleys can be locked into place with bunk pins. To stow, run beds to FULL UP, insert pins, then lower the bottom bunk. To un-stow, run beds to FULL UP, remove pins, then lower both bunks until the top bunk rests on its stop and the lower bunk is at the desired height.
- Lowering Sofa/Dinette Arm: In sofa/dinette configurations, bracket arms can be lowered by removing lockpins, pulling up slightly on the arm, pulling it out, gently lowering, and re-inserting lockpins.
- Adjustments:
- Timing: To ensure proper latching and unlatching, the non-motor side of the bedlift system should be set 1/4" to 1/2" higher than the motor side. This involves lowering the system, measuring from the bottom of the lower trolley sofa bracket to the bottom of the C-channel, unplugging the motor, releasing the brake, incrementally cranking the bed lift on the non-motor side with a 1/2" socket wrench, re-measuring, applying the brake, plugging in the motor harness, and replacing the cap.
- Upper Trolley Tab Rotation: The upper trolley tabs can be rotated to adjust the space between the bed platform and the upper bunk stop. This requires lowering the upper bunk, removing the bunk platform by detaching clevis pins and washers, removing the screws securing the tab bracket to the travel block, flipping the tab bracket 180 degrees, re-attaching it, placing the bunk platform, securing it with pins, and reattaching hardware pins.
- Lower Bunk Trolley Tab Installation: After removing sofa/dinette brackets, trolley tabs can be added to the lower trolleys to accommodate a second bed platform. This involves lining up hooks on the trolley tab bracket with channels in the travel trolley, pushing the brackets in, pushing the bracket down to lock, and inserting a stop screw or lock-up mechanism above the slotted trolley tab.
Maintenance Features:
- Low Maintenance: The bed lift system requires very little maintenance.
- Corrosion Prevention: Chains are pre-lubricated and nickel-plated. Bearings are sealed, and all parts are plated or powder-coated for durability.
- Cleaning: Keep mechanisms clean and free of debris. Inspect vertical trolley channels for dirt after use and clean as necessary.
- Lubrication: After cleaning, a light application of dry silicone spray on the inner sides of the trolley channels will improve performance, reduce noise, and decrease amperage draw.
- Troubleshooting Guide: The manual includes a comprehensive troubleshooting table addressing common issues such as the bed not moving, moving in one direction only, stopping partway, not staying level, or failing to stop at preset points. Solutions range from checking battery charge and power connections to replacing modules, switches, or contacting Lippert Customer Service for motor/brake assembly issues.
- Emergency Manual Operation:
- Raising: Unplug the motor harness, release the brake (move lever to "OFF"), remove caps from cranking points (top of front c-channels, opposite motor side), manually crank with a 1/2" socket and ratchet (easier with two people), apply the brake at the desired height, and reconnect the motor harness.
- Lowering: Unplug the motor harness, release the brake (move lever to "OFF" – the bed(s) will drift downward), re-apply the brake at the desired height, and reconnect the motor harness. A CAUTION warns to ensure no people, pets, or obstacles are below the bed platforms and to keep hold of the brake lever during lowering.
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