The Happijac Bed Lift system is a popular solution for maximizing interior space in vans and recreational vehicles. By elevating the sleeping area, it creates additional storage and living space below. However, successful installation requires precision, attention to detail, and a clear understanding of the mechanical components involved. This guide provides a step-by-step breakdown of the installation process based on official instructions and technical documentation.
Overview of the Installation Process
The installation of a Happijac Bed Lift system is a multi-stage process that involves careful planning and execution. Key stages include preparation and wall alignment, track installation, motor and drive shaft connection, bed frame construction, and final adjustments. Each step is critical to ensuring the system functions smoothly and safely.
The documentation from Happijac and user experiences emphasize the importance of structural integrity, proper alignment, and thorough testing before finalizing the installation. The system is designed to be modular and upgradeable, allowing users to transition from a manual to an electric version with minimal effort.
Stage 1: Preparation and Wall Alignment
Before installing the Happijac Bed Lift, it is essential to ensure that the walls of the van or RV are perfectly square. Any deviation from a true right angle can compromise the functionality of the system. Users should verify that the structure is free of angles and that all measurements from top to bottom and across are consistent. The maximum allowable error is less than 1/4 inch when comparing opposing distances (e.g., front-to-back on the driver’s and passenger’s sides, and diagonals).
It is also recommended to retain the cross beams that come with the tracks, as they help maintain the squareness of the structure and make handling easier during installation. To reduce noise from the chain mechanism, users are advised to place velcro strips on the metal surface behind the chain where it may come into contact during movement.
Stage 2: Track Installation
The next step involves mounting the tracks for the bed lift system. The walls to which the tracks will be attached must be extremely sturdy and connected to the chassis on at least three sides. This ensures that the system remains stable and secure during operation.
To install the tracks, users should mount them as high as possible to maximize headroom. In some cases, it may be necessary to cut slits in the ceiling to allow the top notches of the tracks to extend upward. To hold the tracks in place during installation, users can place a stack of scrap wood under each leg. This allows for precise positioning before securing the tracks with screws.
It is crucial to measure the position of the tracks multiple times—ideally three times—to ensure they are centered and aligned with the van’s centerline. The legs should be installed at a 90-degree angle to prevent them from converging or diverging as they extend downward. Start by securing two screws at the top of the tracks, then measure the distance between the bottom of the legs and install two more screws at the bottom. Once the positioning is confirmed, all remaining screw holes can be filled.
Stage 3: Motor and Drive Shaft Connection
After the tracks are securely mounted, the next step is to connect the motor and drive shaft. Proper alignment of the motor is critical to avoid mechanical issues. Users should ensure that the mounting plates for the motor are at the same height before installing the drive shaft. This helps maintain balance and ensures smooth operation.
The motor can be installed according to the provided instructions, and users should decide whether to orient the motor inward or outward based on their specific setup. Screws are provided to secure the motor in place. The system is designed to be upgradeable, meaning that manual jacks can be converted to electric versions with the addition of a Motor Drive Assembly Kit and, if necessary, a Wiring Kit.
Stage 4: Building the Bed Frame
The bed frame is a critical component of the Happijac system, as it must support the weight of the mattress and user while allowing for smooth movement. The system comes with end bars that can be mounted to the tracks. Users can construct the bed frame using aluminum sidebars and cross beams for structural support. A common approach is to use 6061-T6 Structural Aluminum Angle for the sidebars and 6061-T6 Aluminum Rectangular Tubes for the cross beams.
A bed platform can be constructed using 1/2-inch Baltic birch plywood, which provides a sturdy base for the mattress. To ensure proper ventilation, users can cut slits into the plywood to allow airflow. It is also important to ensure that the end bars provided with the system have sufficient clearance to move freely without hitting the walls, especially in vans with sloped ceilings.
Once the frame is assembled, users should test the system to check for smooth operation. Some initial jerking is normal when the bed is empty, but adding a mattress or simulating its weight should help smooth out the movement.
Stage 5: Final Checks and Adjustments
The final stage of the installation involves checking and adjusting various components to ensure optimal performance. Users should inspect the chain tension and make any necessary adjustments. In some cases, the chains may remain loose even after replacement, and a practical solution is to add weather stripping to the metal surface to reduce noise from chain contact.
Additional features such as recessed and ambient lighting can be installed at this stage. When wiring these components, it is important to leave enough slack in the cables to accommodate the full range of motion of the bed. This ensures that the wiring does not become strained or damaged during use.
Users should also test the system thoroughly, ensuring that all components function as expected. Any irregularities in movement or tension should be addressed before finalizing the installation.
Considerations for Electric Conversion
For users who prefer the convenience of an electric system, Happijac offers an upgrade path for mechanical jacks. The Motor Drive Assembly Kit allows for the conversion to an electric version without the need for a complete replacement of the jack. If the camper is not prewired for electric jacks, a separate wiring kit is required. This upgrade enables remote control of the jack system, enhancing usability and convenience.
Safety and Maintenance Guidelines
The Happijac Camper Jack User Manual includes several important safety guidelines for users of the system. These include:
- Never raise the jacks above the red safety line marked on the inner leg.
- Always reset the locking lever to the up position when the jacks are not in use.
- Use 12-inch square 3/4-inch plywood support pads under each jack to prevent sinking into the ground.
- Avoid using the jacks on uneven ground or when the wind is blowing forcefully.
- Secure the camper with tie-downs when stored outdoors.
- When leveling the camper on a truck, always disconnect the tie-downs before using the jacks.
These precautions are essential for preventing damage to the system and ensuring the safety of the user.
Final Notes on Installation
The Happijac Bed Lift system is a powerful tool for optimizing space in a van or RV, but it requires careful planning and execution. Users should take the time to measure and align all components precisely, and they should not hesitate to make adjustments if the system does not operate smoothly. While the process can be complex, the result is a highly functional and space-efficient living area.
One of the key challenges users may face is the limited availability of the system, as it must be purchased through a certified dealer. However, with the right preparation and attention to detail, the installation can be completed successfully, providing long-term benefits in terms of space and comfort.
Conclusion
The Happijac Bed Lift system is a versatile and effective solution for maximizing interior space in vans and recreational vehicles. By following the detailed installation steps provided in the technical documentation, users can ensure a secure and functional setup. The system is designed to be modular, allowing for upgrades such as electric motor integration. With proper installation and maintenance, the Happijac Bed Lift can significantly enhance the usability and comfort of a mobile living space.