Lippert Vela Pop Up Bedienungsanleitung

Vela Pop Up

Roof System

Class B (EU)

OEM INSTALLATION MANUAL

Rev: 05.10.2021 Page 2 CCD-0004279

TABLE OF CONTENTS

Introduction 2

Safety 2

Resources Required 3

Preparation 3

Pop Up Van Roof Preparation 3

Pop Up Van Assembly Preparation 7

Installation 10

Pop Up Assembly 10

Front Brow 12

Electrical Connections 16

Wiring Diagram 16

Operation 27

Post Installation Check 27

Introduction

The Lippert Pop Up Camper Van is a manually operated, roof-mounted sleeper extension. The Pop Up

Camper Van has a hard roof with a canvas body that includes screened windows for added ventilation

and comfort.

For information on the assembly or individual components of this product, please visit:

lippertcomponents.eu

Note: Images used in this document are for reference only when assembling, installing and/or operating

this product. Actual appearance of provided and/or purchased parts and assemblies may differ.

Safety

Read and understand all instructions before installing or operating this product. Adhere to all safety labels.

This manual provides general instructions. Many variables can change the circumstances of the instructions,

i.e., the degree of difficulty, operation and ability of the individual performing the instructions. This

manual cannot begin to plot out instructions for every possibility, but provides the general instructions,

as necessary, for effectively interfacing with the device, product or system. Failure to correctly follow the

provided instructions may result in death, serious personal injury, severe product and/or property damage,

including voiding of the Lippert limited warranty.

Failure to follow instructions provided in this manual may result in death, serious personal injury

and/or severe product and property damage, including voiding of the component warranty.

The “WARNING” symbol above is a sign that a procedure has a safety risk involved and may cause

death or serious personal injury and/or severe product or property damage if not performed safely

and within the parameters set forth in this manual.

Make sure unit is fully supported and secured per manufacturer's recommendations before working

on or underneath the unit or death, serious personal injury and/or severe product and property

damage, including voiding of the component warranty, may occur.

Rev: 05.10.2021 Page 3 CCD-0004279

Always wear eye protection when performing service, maintenance or installation procedures.

Other safety equipment to consider would be hearing protection, gloves and possibly a full face

shield, depending on the nature of the task.

Resources Required

Preparation

Note: All dimensions are in millimeters unless otherwise specified.

Pop Up Van Roof Preparation

1. Make sure van chassis is level.

2. Make sure van chassis is properly supported and secured.

A. Engage brakes.

B. Chock all tires.

C. Open van side doors to provide access to roof from inside.

3. Construct and position scaffolding (Fig. 1) to safely access and work on van chassis roof.

• 2-3 persons, depending on task

• Cordless or electric drill

• Assorted drill bits

• Caulking gun

• BETACLEANTM 3350 (cleaner)

• BETAPRIMETM 5404 (primer)

• BETAMATETM 1100N-1F (adhesive)

• Merbenit®SF50 adhesive

• Lint-free wipes

• Kiwi®Camp Dry water repellent

• Scaffolding

• Cutting pattern/jig

• Cutting tool for sheet metal

• Permanent marking method

The “CAUTION” symbol above is a sign that a safety risk is involved and may cause personal injury

and/or product or property damage if not safely adhered to and within the parameters set forth

in this manual.

Fig. 1

Rev: 05.10.2021 Page 4 CCD-0004279

4. From inside the van, using the van ceiling frame as a reference, drill a 10 mm diameter hole through

the roof to aid in the positioning of the cutting mask (Fig. 2).

A. Using the drilled reference hole, position the cutting mask onto the van chassis roof.

B. Use a permanent marking method to outline the cutting mask.

Fig. 2

5. There are two different size roof cutouts; 1150 mm or 1050 mm. Use an appropriate cutting tool and

follow the cutting mask outline to create a 1150 mm or 1050 mm (+/- 4 mm) x 630 mm (+/- 4 mm)

opening.

Note: The 1050 mm cutout is offset to the right side of the camper van by 100 mm off the centerline.

A. For long and mid-length vans, refer to dimensions in figure 3 (1150 mm cutout) and figure 4 (1050

mm cutout).

B. For short length vans, refer to dimensions in figure 5 (1150 mm cutout) and figure 6 (1050 mm

cutout).

C. De-burr and clean the cut edges.

D. Coat the cut, de-burred and cleaned edges with an anti-corrosive material.

Fig. 3

Rev: 05.10.2021 Page 5 CCD-0004279

Fig. 4

Fig. 5

Rev: 05.10.2021 Page 6 CCD-0004279

Fig. 6

Chassis

Detail C Section A-A

Pay attention to electric cables entering

the passenger compartment.

943

Section B-B

Fig. 7

6. Use the lower pop up component (the base) as a locating template. Position the template +/- 3 mm on

each side. Refer to dimensions in figures 3-7.

7. Use adhesive tape to mark the outline of the template. Leave at least a 6 mm gap between the

template and the tape all around. This creates a bonding area for future sealant. Refer to the

dimensions in figures 3-7.

Rev: 05.10.2021 Page 7 CCD-0004279

Pop Up Van Assembly Preparation

1. Place the pre-assembled pop up component upside down on a clean work table.

Note: Make sure the work surface is clean of dirt and debris to protect the top component from acquiring

blemishes and scratches.

A. Before applying cleaner to the lower pop up component, refer to figure 9 for a 1100 mm wide

cutout opening and figure 10 for a 1000 mm wide cutout opening. Use BETACLEAN 3350 cleaner

and lint-free wipes to prepare the mating surfaces of the lower pop up component.

B. Before applying cleaner to the camper van roof, refer to figure 11 for a 1100 mm wide cutout

opening and figure 12 for a 1000 mm wide cutout opening. Use BETACLEAN 3350 cleaner and

lint-free wipes to prepare the mating surfaces of the camper van roof.

C. Before applying primer to the lower pop up component, refer to figure 11 for a 1100 mm wide

cutout opening and figure 12 for a 1000 mm wide cutout opening. Apply BETAPRIME 5404 primer

to the previously cleaned mating areas of the lower pop-up component as follows:

I. Before using, shake the primer can at least one full minute until the rattling of the internal

mixing spheres can be heard.

II. Apply the primer only one time in the same direction. Avoid primer overlapping.

2. With the lower pop up component still in its upside down position, refer to figure 8 for a 1100mm

wide cutout opening and figure 8 for a 1000 mm wide cutout opening for the appropriate

adhesivepattern.

A. Use BETAMATE 1100N-1F to create two continuous beads of adhesive, as defined in figure 8.

B. Apply enough BETAMATE 1100N-1F adhesive so that when the lower pop up component is

Fig. 8

installed onto the van roof the adhesive will spread out far enough to also act as asealant.

C. Additionally, create an adhesive loop across the back (rear) corners of the lower pop up

component as follows:

I. Start applying adhesive along a side 300 mm away from a rear corner, then run the bead of

adhesive down to the corner.

II. Continue applying the adhesive across the backside of the component and around the

opposite corner.

III. Then, continue applying the adhesive up 300 mm along the side.

IV. Finally, continue applying the adhesive back across to the beginning of the bead.

V. Connect the adhesive beads to complete the loop.

Rev: 05.10.2021 Page 8 CCD-0004279

Fig. 9

Fig. 10

Rev: 05.10.2021 Page 9 CCD-0004279

Fig. 11

Fig. 12

Rev: 05.10.2021 Page 10 CCD-0004279

Fig. 13 Fig. 14

Installation

Pop Up Assembly

In addition to using the prepared cut out for the positioning, also use the references—adhesive tape

or permanent markers—performed in step 7 of the Pop Up Van Roof Preparation procedure in the

Preparationsection.

1. Lift the pop up assembly over the van chassis roof (Fig. 13), positioning it over the prepped cut out.

2. Lay the pop up assembly onto the van roof. For additional positioning information, refer to figure 15

for long and mid-length vans and figure 16 for short vans.

3. Adjust the pop up assembly into position. Make sure the pop up is firmly seated (pushed down)

(Fig.14). Remove the vacuum lift and open the top.

4. While wearing nylon gloves, use your finger to spread all of adhesive that has oozed out around the

perimeter of the top. Make sure to add more adhesive to close all gaps.

5. Remove the adhesive tape from the pop up that was used to mark the layout.

6. Use straps across the front and back of the pop up to hold the top in place while adhesive is curing.

7. Lower the top back down and position the vacuum lift back on top for added weight.

8. Apply pressure to the assembly (Fig. 14). Make sure enough adhesive spreads out around the pop up

assembly to act as asealant.

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