PNP BED -LIFT - 2 - Operating Instructions - HappiJac

PNP BEDBED-LIFTA Division of Lippert Components, Inc.Product Usage:USERS MANUALAnd Troubleshooting GuideThis product is designed and intended ONLY to be used as aBed-Lift mechanism. Any other use of this system will voidany and all written or expressed warranties and indemnifyHAPPIJAC COMPANY from any harm which may occur asa result of any other use or misuse of this product.Operating Precautions:CHECK. To be sure the attaching pins are securelyfastened at all 4 corners of the bed platformbefore towing the trailer, or using the bed(s).ALWAYS. Raise the bed(s) to the FULL UP position whenthe trailer is being towed TO AVOID DAMAGETO THE BED(s) as a result of bouncing.NEVER . Operate the bed(s) with any items other thanbedding on the bed platform.NEVER . Travel with any items other than bedding on thebeds. Loose items can become projectiles.NEVER . Operate the bed(s) when persons are on the bedplatform.NEVER . Hang from, or hang more than 20 pounds fromthe cross-connecting shaft.-2-Operating Instructions:The bed(s) is/are operated from thecontrol switch. Pressing and holdingthe switch in the UP position movesthe bed(s) upward. Pressing andholding the switch in the DOWNposition, moves the bed(s) downward.Limit switches are used to stop thebed(s) at their maximum travel range.However, the bed(s) can be stopped andused at any desired height. Once thecontrol switch is released, the brake setssecuring the bed(s) in that position.Limit Switches(Top & Bottom)User configuration options:The following user configuration options are possible.Trolley Tab SettingsThe “Trolley tabs” are the angular pieces which support the bedplatform. These can be adjusted upward or downward, or flipped180 degrees. The purpose for this adjustment option is to providegreater flexibility in configuring the system for users specificneeds. Examples would include: Creating more headroom whenthe beds are up or creating more spacing between the beds in a“bunk bed” (2 bed) system. See the following illustrations.Examples of optional Trolley Tab configurations.ALWAYS. Ensure that the areas above, below and adjacentto the bed(s) are free from obstructions beforeoperating the bed(s).ALWAYS. Check before operating bed(s) to ensure beddingis not over-hanging the ends of the beds where itcould become entrapped.ALWAYS. Exercise care when loading cargo/vehicles in thebed area to avoid damage to the bed mechanism.ALWAYS. Properly secure loads in the bed area to avoiddamage to the bed mechanism from shifting orfalling loads.Single bed units can be easily upgraded to bunk bed (2 bed) unitsby installing the trolley tabs to the existing second trolley andadding a bed platform and mattress.

Bunk Stop Settings (Upper trolley stop):-3The upper bunk trolley is free floating and is carried bythe lower trolley. The height at which this trolley stops isset by“stop blocks” which sits inside the trolley rails.To changethis stop, remove the 2 screws which hold it inplace andmove it to the desired height. (All 4 corners)Bunk Stop Block-The HAPPIJAC Bed-Lift system requires very little maintenance.The chains are pre-lubricated and nickel plated to prevent corrosion.All bearings are sealed and all parts are either plated or finished witha durable powder-coat finish.The only required maintenance involves keeping the mechanism cleanand free of debris. When cleaning the trailer after use, inspect thevertical trolley channels for dirt or debris and clean as necessary. Aftercleaning, a light application of silicone spray on the inner sides of the trolleychannels will improve performance and reduce noise and amperage draw.(Silicone spray can be purchased at hardware & auto parts stores.Look specifically for the brands which provide a small spray tube.This makes application much easier.)Troubleshooting & Repair:SymptomStowing The Top Bunk: (2 BED CONFIGURATION)The bed lift system has a stow feature for the top bunkwhich leaves it in the travel position at the ceiling whileallowing the lower bunk to be set at a usable height.To Stow1. Run the beds to the FULL UP stop.2. Insert the locking pins through the trolley railsas shown in the adjacent photo.3. Lower bottom bunk to desired height.-4-Maintenance:Possible CauseBed will not move eitherup or down when switchis pressed.See diagnostic flowchart page 51 No or insufficient powerto operate bed2 Faulty control module3 Faulty switch4 Defective motorBed will go one directionwell but not the other.See diagnostic flowcharts pages 6 & 7.1 Defective limit switch2 Faulty control module3 Faulty up/dn switch4 Faulty BrakeBed operates well goingdown, but stops part waygoing up.1 Insufficient power to bed.2 Defective motor/brake assembly.See test on page 10.NOTE: The bunkplatforms removed forphoto clarity only.Platform removal notnecessaryto stow bunk.Bed will not stay level sideto side, or front to back.To Un-stowBed fails to stop ad presetstop point going up.1. Run the beds to the FULL UP stop.2. Remove the locking pins.3. Lower both bunks until the top bunkrests on the bunk stop and thelower bunk is at desired height.Bed fails to stop at presetstop point coming down.Upper bunk (2 bed system)Does not come downsmoothly.1 Broken or loose timing shaft.2 Broken chain sprocket.1 Motor brake not engaging.See test on page 10.2 . Defective limit switch.1 Defective or damaged limitswitch1 Sticky bed carrier. Spray a smallamount of Silicone lubricant up bothinner sides of all 4 rails.(See maintenance section.)

-5Troubleshooting Flow Charts:Problem: Bed(s) will not move either up or downWhen switch is pressed.STARTPress the Up/Dn switch.do the beds make anyNoattempt to move?YesDo you hear a clickingnoise in control module Nonear motor when switchis pressed?Set manual brakerelease lever onmotor to “OFF” Yes Replacefaultyposition. Willbrakebeds move?NoCheck battery chargeorPlug into ACorStart GeneratorYesRun motor &brake test onpage 11.Yes RectifypowerproblemDid the bed move up?NOYESMake certain coach batteriesare adequately charged andYESif possible, plug into ACpower or engage generator.Try again – Problem solved?EndReplacedefectivelimit switchNOMove brake lever to OFFposition then try again.Did beds go up?NoRestore powerand/or groundfrom trailer.Beds move with pinsshorted?NoYesReplace faultylimit switch assy.While pressingswitch in the up NOposition, doesthe bed make anyattempt to go up?Do, do you hear aclick at thecontrol module?Unplug the upper limit switch, then shorttogether the pins protruding from modulePress the switch to up position.Only briefly. (See page 12)NoWill beds move?Test limit switches by removingred plugs and shorting pinsprotruding from module(See page 12)STARTYESCheck 12 VDC& ground inputsto control module.Power and groundGood?Yes-6-Problem: Bed will go down but will not go up.Contact:Happijac CompanyTechnical ct:Happijac CompanyTechnical Support1-800-231-7440NO

-7 -Problem: Bed will go up but will not go down.Wiring Diagram-8-STARTWhile pressingswitch in the down NOposition, doesthe bed make anyattempt to go down?Do, do you hear aclick at thecontrol module?Unplug the lower limit switch,then short together the pinsprotruding from modulePress the switch to downposition. Only briefly.(See page 12)All outputs are marked on theunderside of the moduleDid the bed move down?YESYESMake certain coach batteriesare adequately charged andif possible, plug into ACYESpower or engage generator.Try again – Problem solved?Replacedefectivelimit switchNOContact:Happijac CompanyTechnical Support1-800-231-7440EndNO3-pin2-pinRJ-11 COM. CABLENote: MUST BEreverse/cross overcable – standard telephonecable will not workOPERATIONAL NOTES:Within the control module is a tri-state relay. This relay transfers bi-directional powerfrom the trailer power source to the bed lift motor and to the brake solenoid to release thebrake. The up/down switch when activated closes the ground path to one of two solenoidcoils within the relay causing the coil to energize and close the appropriate set of relaycontacts. IE: the up contacts to move the beds up and the down contacts to move the beddown.The limit switches are normally closed switches and are wired in series with the up/downswitch. Therefore, until the beds reach and trip (open) the limit switch, there is a groundpath through the micro switch and up/down switch and the bed moves. Once the microswitch is reached and tripped (opened), this ground path is broken and the motor stops andthe brake setsIn some systems, the trailer manufacture may have added and additional switch as an“ON/OFF” or “LOCK’OUT SWITCH”. If so, this switch may be wired in one of twoways. It will either be used to break the switch common lead to the Up/Down switch, inwhich case there will be additional wires coming to the back of the up/down switch, orit may be used to kill the primary power from the trailer to the PNP Control Module, inwhich case there will be no power at the modules main power input until this switch isclosed.

- 9-- 10 -EMERGENCY MANUAL OPERATIONNote: Before manually cranking thebed-lift, the brake must be releasedand the motor unplugged.CRANKING POINTFOR MANUAL OPERATIONMotor PlugBrake releasefor manualoperation.Use ½” hex socket wrench.Cranking is easier if 2 people crank,one on each side of the coach.To Manually Raise the beds:1. Unplug the motor2. Release the brake3. Turn hex shaft using a ½” ratchet wrench.4. Re-apply brake at desired bed height.5. Reconnect motor plug.To Manually Lower the beds:1. Unplug the motor2. Release the brake3. Apply downward pressure to the bed platform.Bed will slowly drift downward.4. Re-apply brake at desired bed height.5. Reconnect motor plug.CAUTION: When beds are not beingmanually raised or lowered, theBRAKE MUST BE SETor beds will drift down and will damageobjects or vehicles placed below the beds.