Magliner CooLift CTA Series User manual

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CooLift®
Serial #: _________________________________
Date of Purchase: ________________________
Owner’s Manual
IMPORTANT: Read entire manual before operating
For CooLift models with electric hydraulic lift, no propulsion
(CTA-- models)

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CooLift®
Warranty
Magliner products have a one (1) year warranty (unless otherwise specied) from the date of
purchase against defects in workmanship or material. Any part or component, except items covered
by warranties of other manufacturers, returned to the factory or service center freight prepaid
by the owner, found upon examination by Magline, Inc. to be defective or the result of improper
workmanship by the factory will be repaired or replaced without charge and returned to the owner
freight prepaid by Magline, Inc.
Alterations of Magliner products void any warranty or liability on the part of Magline, Inc. Magline,
Inc. does not guarantee product capacity if alterations are made.

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CooLift®
Table of Contents
Introduction, Safety Instructions ...........................................................................................................4
Operating Labels...................................................................................................................................5
General Specications ..........................................................................................................................6
CooLift Pallets .......................................................................................................................................7
Controls -- General Operation..........................................................................................................8-11
Battery Instructions........................................................................................................................ 12-14
Manual Operation ...............................................................................................................................15
Troubleshooting............................................................................................................................. 16-17
Replacement Parts List ................................................................................................................. 18-20
Inspection / Maintenance Checklist................................................................................................21-27

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CooLift®
Thank you for purchasing the Magliner CooLift! If you have any questions regarding your new
Magliner product please call our customer service department at 1-800-MAGLINE (624-5463) or
[phone]. Please read this manual thoroughly to become familiar with the safe operation and
maintenance of your new Magliner CooLift.
General Safety Instructions
• Carefully read this entire manual before using your Magliner CooLift.
• Keep hands and feet away from all moving parts.
• Always stand clear of lifting platform area when operating.
• Do not attempt to use the Magliner CooLift on a truck ramp.
• Engage the holding brake whenever in a stopped position.
• Keep the Magliner CooLift in an upright position at all times.
• Do not utilize Magliner CooLift as a lifting device for anything other than a CooLift pallet.
• Do not use the Magliner CooLift to transport people.
• A routine check of the CooLift should be performed daily that includes, but not limited to:
checking for any leaks in the hydraulic or brake system; making sure the containment strap
functions correctly; making sure the lift deck raises and lowers smoothly without excessive
slowing or shuddering; checking the brake system to ensure proper slowing, stopping, and
holding functions.
• Always use the containment strap when moving loads with the Magliner CooLift.
• When transporting a load, always use the handles provided at the user end of the CooLift
in order to provide quick access to the braking system should immediate stopping be
required.
• Operator should be positioned uphill from CooLift when descending on natural grades,
sloping or uneven surfaces.
• Use hand brake to control speed.
• Avoid making sharp turns.
• Always use a Magliner battery charger to charge your battery.
• Do not exceed the pallet capacity limit.
• Brake and hydraulic uids are a slip hazard on any ooring surface; if a leak occurs it
should be cleaned up immediately and completely.

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CooLift®
Please follow the reminder labels found on your CooLift unit.
NO FORK
CooLift
®
Capacity:
1,200 lbs. with 43" CooLift
®
pallet
1,350 lbs. with 48” CooLift
®
pallet
1,500 lbs. with 53" CooLift
®
pallet
1-800-MAGLINE (624-5463)
www.magliner.com
U.S. Patent No. 8,282,111 & 8,894,076
Always stand clear
of lifting platform
area
when operating
Keep hands and feet
clear of lifting platform
Safety Instructions
• Read and understand operating instructions
before using
• Always inspect CooLift and pallets for damage
before using. Do not use if there are signs of
damage, improper maintenance or load shift
• Do not exceed capacity limit
• NO RIDING — Riding on the CooLift could
cause serious injury
• DO NOT USE ON TRUCK RAMPS
• Use caution on natural grades; operator
should be positioned uphill from cart when
descending, use brake to control speed, no
sharp turns
• Always apply holding brake and lower lift
before unloading pallet or leaving CooLift
unattended
WARNING
WARNING

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CooLift®
General Specications CTA43 CTA48 CTA53
Corresponding pallet size 43 inch 48 inch 53 inch
Capacity 1,200 lbs 1,350 lbs 1,500 lbs
Weight without battery 193 lbs 193 lbs 185 lbs
Weight with battery 221 lbs 221 lbs 213 lbs
Overall height 62 inches 62 inches 62 inches
Overall width 19 inches 19 inches 19 inches
Overall depth 60 inches 60 inches 60 inches
Operating temperature* -20 to 120°F -20 to 120°F -20 to 120°F
*NOTE: When the outside temperature is below 30°F the CooLift should not be left inside the truck
overnight and should never be left inside a freezer or a cooler for extended periods of time. Extended
exposure to subfreezing temperatures will adversely affect CooLift performance and increase cycle
time.
Battery Specications
Weight 28 lbs (battery box with battery cells)
Voltage 24v (two 12v battery cells)
Battery cells Sealed lead acid - maintenance free
Fluid Specications
Brake uid DOT 3 or DOT 4
Hydraulic uid MIL-PRF-5606
CooLift without
bulk head
CTA53
CooLift with
bulk head
CTA43 CooLift with
bulk head
CTA48

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CooLift®
Pallets
Buttons for attaching beginning of
stretch wrap
General Pallet Information:
• Always load within capacity limit.
• Always load within pallet footprint; do not allow load to hang over pallet.
• CAUTION: When using any multiple load handling system (such as a triple-double) to move
the CooLift pallets, do not spread the forks while underneath pallet as it may result in pallet
failure.
• Store in upright position in cool, dry location.
• Do not drop.
• Do not stand upon.
• Wash with mild soap and water.
• Do not use if damaged.
• Make sure to interlock empty pallets when stacking.
• Only stack pallets when empty.
• Do not make modications.
• Secure load before transporting.
• Use for intended purpose only.
Ergonomically placed hand
holes for easy carrying
Sizes Capacity Part Number
43” pallet 1,200 309344
48” pallet 1,350 309345
53” pallet 1,500 309346
Pallet design allows
for any size pallet to
stack on top of any
other size pallet.
Anti-slip tape
reduces product
from shifting

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CooLift®
User Controls
A) Main Power Switch – provides power to hydraulic unit for raising and lowering the deck.
B) Circuit Breaker – helps to protect the components should an electrical short or overload occur.
C) Charging Port – for charging the CooLift battery with an approved Magliner AC charger.
D) Deck Positioning Switch (up/down) – used to raise and lower the lift deck.
E) Brake Lever – used for slowing and stopping the momentum of the CooLift.
F) Holding Brake Latch – used to keep the CooLift from rolling inadvertently – Always engage
holding brake whenever CooLift is unattended.
G) Cord Storage Brackets – holds the AC built-in battery charger input cord when not in use.
H) Containment Strap – should be used to secure loads during transport.
I) Operator Handles – foam cushioned, ergonomic handles for lift control.
J) Manual Pump Handle – handle and storage bracket when not in use.
K) Manual Pump Handle Slot – for attaching manual pump handle in the event power is unavailable.
General Operation of the Magliner CooLift
Storage and Limited Use of Holding Brake
1) Engage the holding brake whenever leaving the CooLift unattended.
2) Pallets on the Magliner CooLift should always be in the down position when not moving.
3) Keep hands, feet and all items clear of the moving parts of the CooLift.
4) Never place hands or feet under a loaded elevated pallet.
5) The holding brake is intended to be used for limited periods of time only.
6) Store the CooLift on a hard level surface.
A
B
C
D
E F
GG

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CooLift®
H
K
J
I

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CooLift®
General Operation of the Magliner CooLift
A) Storage and Limited Use of Holding Brake
1) Engage the holding brake whenever leaving the CooLift unattended.
2) Pallets on the Magliner CooLift should always be in the down position when not moving.
3) Keep hands, feet and all items clear of the moving parts of the CooLift.
4) Never place hands or feet under a loaded elevated pallet.
5) The holding brake is intended to be used for limited periods of time only.
6) Store the CooLift on a hard level surface.
CooLift with product strapped to deck
Front Underside View
B) Loading a pallet on the Magliner CooLift
1) Make sure CooLift deck is in down position.
2) Push the CooLift under the pallet until fully inserted and the back of the pallet is touching
the back of the cart or the bulk head if one is installed.
3) Press and hold the up switch until the lift deck is fully raised (this is noticeable by the sound
change of the running hydraulic pump and the stop of upward motion of the pallet).
4) Engage the holding brake by depressing the brake lever back toward the horizontal handle
with one hand and ipping the holding brake latch into one of the provided notches to hold
it in place.
Note: Make sure the deck is in the up position prior to fastening the containment strap.
5) Fasten the containment strap to secure the load by: a) rmly grasping the end of the
strap; b) pulling it out from the roll directly over the center of the load taking care not to twist
the strap; c) extending strap far enough to snap into position; and d) hooking strap to the
containment lock located at the lower front end of the cart (see Front Underside View).
6) The maximum stacking height for all models (CTA43, CTA48 and CTA53) models is 50”.
However, never stack a load that is higher than your line of vision.

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CooLift®
Figure 1: CooLift secured under a loaded
pallet with the holding brake engaged
Figure 2: CooLift strapped into truck for transport
D) Unloading a pallet from the Magliner CooLift
1) Position the cart in place on a level surface and engage the holding brake.
2) Lower the deck completely.
3) Unlock the containment strap from the lock by lifting the tab and sliding the latch out.
4) Walk the strap back into position on the roll.
5) Disengage the holding brake by pulling the brake lever back until the latch releases.
E) Transporting the Magliner CooLift inside the truck
Note: It is important to keep the CooLift upright at all times.
1) If you are transporting the CooLift on a truck that has loaded pallets, insert the CooLift
completely under a fully loaded pallet and toggle the up switch until the lift deck makes
contact with the bottom of the pallet but does not lift and engage the holding brake
(Figure 1).
2) If there are no loaded pallets on the truck, the CooLift should be parked next to the wall
and strapped in with the holding brake engaged (Figure 2).
C) Transporting a pallet with the Magliner CooLift
1) When transporting a pallet with the CooLift the operator should always use caution on
natural grades. Be positioned uphill from cart when descending, use brake to control speed
and make no sharp turns.
2) Care should be taken to address any sidewalk ramps or door thresholds to help maintain
stability in the load.
3) Use caution at all sloping or uneven surface areas and make any nal positioning changes.
4) Depress the down switch and hold it until the CooLift deck has lowered completely. Note: it
is possible to have the pallet sitting on the oor and the deck still engaged to the bottom of
the pallet if the deck has not been completely lowered.
5) Remove the CooLift from under the pallet.

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CooLift®
Battery*
General Battery Warnings:
• Do not connect accessories to the battery; this will cause
premature battery failure.
• Unauthorized modication could create a hazardous
condition and result in serious injury.
• Batteries contain sulfuric acid, which can burn eyes,
skin, clothes, etc. Use caution! Always wear gloves
when working with batteries. If contact occurs, ush
immediately with water and get medical attention.
Protect surfaces from battery damage by placing
batteries on rubber or plastic surfaces.
• To prevent electrical shock, do not touch non-insulated
parts of the charger output connectors, battery
connectors or battery terminals. Do not use connectors
that are cracked, corroded, or do not make adequate
electrical contact. Use of damaged or defective
connectors could result in re or electrical shock.
• Keep sparks, ame and smoking materials away from
batteries.
• Batteries can supply a large amount of current. Do not wear jewelry or watches when working on
the batteries as an accidental shorting could occur and cause severe burning.
• Only qualied technicians should service your Magliner CooLift power supply system.
• Disconnect the battery box by unplugging the main wiring harness before attempting to replace
any electrical components.
• Only use authorized Magliner CooLift replacement parts.
Battery Life
The Magliner CooLift is powered by two 12-volt storage batteries. The pump motor draws current
from the batteries based on the amount of effort required to meet load being lifted. Testing and
research has been done to ensure a fully-charged battery will allow the user to go through a normal
workday without recharging the system; however, extreme temperature ranges and extreme loads
can have an effect on the amount of power available during one charging cycle.
NOTE: The battery must be charged within 6 months of storage to prevent self-discharge. If the
battery is not charged within 6 months of storage, permanent loss of capacity may occur.
Battery Charging
A built-in Magliner AC charger (part #63004 when using a common 120v domestic or 230v
international outlet) is capable of safely charging your CooLift battery. This charger uses standard
household power.
NOTE: When using the AC charger, please move the red switch (located next to the power switch) to
the voltage that is normal to your location.

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CooLift®
Battery Charging Warnings:
Use only Magliner chargers designated for use with CooLift.
Do not expose charger to rain or snow.
To prevent risk of re, use the charger only in a dry, well
ventilated room without ammable uids or explosive gases.
Do not allow clothing, blankets or other material to cover
battery charger during charging process. Ensure there is proper
ventilation in area used for battery charger and batteries.
Use of an attachment not recommended or delivered by the
battery charger manufacturer may result in a risk of re,
electric shock or injury to persons.
Avoid using an extension cord as it can present risk of re and electrical shock. Never use a
household extension cord if the charger plug does not reach outlet. If an
extension cord must be used, use a three conductor No. 14 AWG (or heavier) cord with
proper ground, in good electrical condition and kept as short as possible.
Make sure the cord is located such that it will not be a trip hazard or otherwise subject to
damage or stress.
Do not operate a charger with a damaged cord or plug – replace immediately.
Do not operate a charger if it has received a sharp blow, been dropped, or otherwise
subjected to damage or stress.
Do not disassemble the charging unit.
To reduce risk of electrical shock, unplug the charging unit from the AC power
supply source before attempting any maintenance or cleaning.
Always unplug the charging unit before operating the Magliner CooLift.
Always use battery chargers supplied by Magline, Inc. Other battery charging units could
cause damage to your batteries or personal injury.
Batteries generate gases that can be explosive. To prevent arcing or burning near batteries,
do not disconnect the charger output connector from the charging port when the battery
charger is in operation. If an interruption of the charging cycle is desired, move the battery
charger switch to OFF, disconnect it from the power supply source and then disconnect the
charging connector from the charging port.
To avoid damage to battery charger connectors and cords, disconnect by grasping the plug
body and pulling it straight out of the outlet or receptacle. DO NOT pull on the cord. DO NOT
twist, rock, or pull the connector sideways.
The metal tip on the end of the plug may be hot when it is rst unplugged.
*Battery has a warranty of six (6) months

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CooLift®
Using the AC Charging Unit
1) Connect the AC charger plug to an AC outlet (120v domestic or 230v international).
2) Plug the output cord from the charging unit into the charging port located on the top of the
battery box.
3) Turn the power switch on the charging unit to the “On” position.
4) When disconnecting the charging unit from the CooLift or a supplementary battery box:
a) Turn the charging unit power switch to “Off” position;
b) Unplug the charging unit from the power source (AC outlet);
c) Disconnect the charging unit from the charging port.
A completely drained battery needs 2 hours to fully charge. The LED will illuminate to
indicate one of the following conditions:
Solid Yellow – Battery is charging
Solid Green – Battery has fully charged and is ready for use
Flashing Green – The output is not connected; check all
connectors and fuses
NOTE: Your AC charger model may have two LED lights. If your charger has two LEDs, a solid red
light on the charging unit is an indication the power is on and should remain on the entire time it is
plugged into the power source and the battery.
NOTE: There are two operational fuses on the charging unit located at each end.Aspare fuse is
located adjacent to the main power connection.
Note: Battery may be charged as often as desired. Magline recommends charging at least
once after each delivery route is complete.
Battery Meter Operating Instructions
• Battery meter will show the charged state of the battery whenever the main power switch is
turned ON
• During normal operation, the charged state of the battery is indicated by the number of bars
displayed on the meter
• Full charge is 10 steady bars
• A partial charge is two to nine steady bars
• A low battery is two alternately ashing bars
• While the battery charger is plugged in and charging the battery, the display will repeatedly
scroll across the bars up to the level of charge in the battery
• Full charge is indicated by scrolling across 10 bars
• A partially charged battery is indicated by scrolling across two to nine bars
• When the main power switch is OFF, the battery meter will not display

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CooLift®
Manual Operation of the Magliner CooLift
The CooLift can be raised and lowered manually if the need arises due to a critically low or non-
existent power situation using the manual hand pump handle provided with the unit. To operate the
pump in the manual mode, insert the handle into the pump handle receiver located at the top of the
slotted cutout on the rear access panel of the cart and begin a pumping motion to raise the lift deck.
To lower the deck, slide the handle over the manual release valve screw located directly below the
receiver at the bottom of the slotted cutout and turn it in a counter clockwise direction to release the
pressure and thereby lower the deck. When the lift deck is at the lowest position, the manual release
valve should be tightened to ready the manual pump for the next lift operation. (Note: the lift deck will
not go up if the manual release valve is in the open position while in manual mode and it will not stay
up when operating in a powered situation.)

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CooLift®
The unit does not turn on.
 Is the main switch turned on?
 Has the battery been charged?
 Has the circuit breaker been tripped?
 Is the battery box fully plugged in?
 Check electrical connections for tightness, including battery terminals within the battery box.
The pump is running but the deck is not lifting.
 Is the uid level correct in the reservoir?
 Do you see any leaks in the hydraulic system?
 Is the manual pump release valve open?
 Is the breather cap for the pump reservoir plugged?
The deck lifts to the top position but then gradually lowers.
 Is the manual release valve fully closed?
 Do you see any leaks in the hydraulic system?
The deck lifts OK but lowers slowly.
 Does it go down quicker when opening the manual release valve?
 Do you see any uid leaking out of the gas springs?
The deck lifts slower than usual.
 Is the manual release valve closed all the way?
 Is the uid level correct in the reservoir?
 Do you see any leaks in the hydraulic system?
The brakes are not working or braking unevenly side to side.
 Do you see any leaks in the brake system?
 Is the brake uid level correct in the reservoir?
 If you pump the brake lever several times, does it start working?
 Are both of the calipers mounted tightly to the rail?
The CooLift is not charging up.
 Is the charger working correctly?
 Is the battery box connected correctly?
 Will the batteries charge up when using the charging port located on the side of the battery
box?
 Have all electrical connections been checked?
 Is the internal charger switch in the ON position?
 Is the power plug plugged in the charger socket?
 Is the charger output cord plugged into the battery pack charger port?
Troubleshooting

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CooLift®
The deck is in the up position and will not go down.
 Is there any foreign matter in the linkage system?
 Check for loose wire connections from the switch plate.
The pump runs and will not shut off.
 Turn off main power switch.
 Check the continuity of the starter solenoid.
 Check the continuity of the operator on/off switch.
Hydraulic or brake uid has dripped into the drip pan underneath the CooLift deck.
 Wipe up any uid that may have leaked into the drip pan using shop towels.
Troubleshooting

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CooLift®
Replacement Part Description Part Number
AC charger for 24v battery (for use with common 110v domestic or 230v international outlet) 63004
Axle - 14.3” long for center CooLift wheels 309020
Axle assembly (includes axle and lock nut) for CooLift casters 84501
Back access panel 309077P
Banjo bolt - 10mm x 20mm 80124
Banjo bolt with bleed screw 80135
Battery box (batteries not included) 309101
Battery box assembly (includes batteries) 309100
Battery box cover 309102
Battery cell 12v - 18Ah 61018
Battery charge meter 62033
Brake disc 309050
Brake uid - 12 oz. container 309026
Brake line clip 61019
Brake pads (pair) 309594
Brake pawl for master cylinder 309183
Brake pawl kit 309219
Brake U-bracket for master cylinder 309182
Bulk head for CTA43 309113
Bulk head for CTA48 309332
Cable tie 61052
Caliper assembly 309595
Caliper assembly upgrade kit (required for CooLift units with serial number 4608 and lower
when replacement of brake pads or caliper are required the rst time after March 2015
upgrade) 309596
Caliper brake line assembly 309145
Carriage bolt - 3/8”-16 x 1” long 80127
Caster wheel - 6” x 2” gray at tread 130014
Center wheel - 10” x 2” with deep groove ball bearings 309059
Charger mount bracket 309207
Circuit breaker - 35A 62015
Clamp block for axle/brake caliper mount 309022
Containment strap 309152
Containment strap mounting spacer - all models 309150
Containment strap tongue 309133
Copper washer 80712
Cord for internal battery charger 64018
Cord grip - PG-9 309177
Cord grip - PG-16 309122
Cord grip - PG-21 309124
Cord grip hex lock nut - PG-9 309178
Cord grip hex lock nut - PG-16 309123
Cord grip hex lock nut - PG-21 309125
Corner post assembly 309108

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CooLift®
Deep groove ball bearing for center CooLift wheels 309060
Flat head machine screw 82 degree 5/16”-18 x 3/4” long 80261
Flat washer #10 Type-A 80763
Foam handle sleeve - 9” 302285
Front caster yoke 309098
Grommet - 5/8” ID x 1-1/8” OD x 3/8” wide 309024
Handle mount bracket 302721
Hex head cap screw - 5/16”-18 x 1-1/4” long 80012
Hex head cap screw - 3/8”-16 x 1” long 80025
Hex head cap screw - 3/8”-16 x 1-1/4” long 80026
Hex head cap screw - 3/8”-16 x 1-1/2” long 79988
Hex lock nut - 1/4”-20 80675
Hex lock nut - 5/16”-18 80676
Hex lock nut - 3/8”-16 80603
Hex lock nut ange - 3/8”-16 80624
Hex lock nut w/ nylon insert - #10-24 UNC 80683
Hex lock nut w/ nylon insert - #10-32 UNF 80684
Hex socket head cap screw - 5/16”-18 x 1” long 80038
Hex socket head cap screw - M6 x 20mm 80003
Horizontal brace (handle) 309048
Hydraulic cylinder assembly (includes hydraulic cylinder with tting, 80396 screw and 80754
washer) 59006
Hydraulic uid - 32oz. container 55407
Hydraulic uid additive - 32 oz. container 55418
Hydraulic hose 55408
Hydraulic pump assembly 63013
Hydraulic pump reservoir 59501
Internal charger mount kit 309209
Junction block 309051
Lock washer split ring for #10 screw 80747
Manual pump handle 63014
Master cylinder 309218
Master cylinder brake line 309083
On/off toggle switch - 30A 62016
Operator up/down switch 63019
Pallet stop for CTA43 and CTA48 models 309206
Pan head screw - #8-32 x 1/2” long with external lock washer 80218
Pan head cross recess screw - #10-24 x 2-1/2” long 80004
Pan head machine screw - #10-32 x 3/4” long 80121
Pan head machine screw - #10-32 UNF x 1” long 80123
Pan head machine screw - 1/4”-20 x 3/4” long with locking patch 80257
Pan head machine screw - 1/4”-20 x 1” long 80102
Pan head machine screw - 1/4”-20 x 1-1/2” long 80105
Pan head machine screw - 1/4”-20 x 1-3/4” long 80106
Replacement Part Description Part Number

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CooLift®
Pan head machine screw - 1/4”-20 x 2-1/2” long 80108
Pan head machine screw - 1/4”-20 x 2-3/4” long 80111
Pan head machine screw - 1/4”-20 x 3” long 80110
Pan head machine screw - 5/16”-18 x 1-1/4” long 80150
Plug male - 115v 5-15p 61053
Pump mount plate 309831
Pump starter - 24v DC (solenoid) 63015
Round head machine screw - #10-32 UNF x 7/8” long 80122
Round head machine screw - 5/16”-18 x 1-1/2” long 80115
Saddle plate for CTA43 and CTA48 309341
Saddle plate for CTA53 309151
Spacer 3/4” square foam, self adhesive backing 309217
Steel end cap for vertical loop handle 309049
Straight cotter pin 81142
Switch plate full assembly (includes switch plate with all wiring harnesses installed) - use only
for CooLift units with serial numbers 3999 and lower and does not have a battery meter 309181
Switch plate service kit (includes switch plate with only charge port harness installed) - use only
for CooLift units with serial numbers 3999 and lower and does not have a battery meter 309181S
Switch plate full assembly for units with battery meter (includes switch plate with all wiring har-
nesses installed) - use only for CooLift units with serial numbers 4000 and higher or if
your CooLift has a battery meter 309357
Swivel caster 6” x 2” gray thermoplastic rubber at tread 130066
Vertical handle mount assembly 309087P
Vertical loop handle - LH 309039
Vertical loop handle - RH 309053
Washer for #6 screw - neoprene bonded 80730
Washer for CooLift wheel 80718
Wiring harness for battery box connector plug 62025
Wiring harness for battery charge meter 62032
Wiring harness for battery interconnect 62024
Wiring harness to connect battery box to on/off toggle switch 62023
Wiring harness to connect cabinet charge port to on/off toggle switch 62030
Wiring harness to connect circuit breaker to on/off toggle switch 62020
Wiring harness to connect circuit breaker to pump 62022
Wiring harness to connect pump to on/off toggle switch 62021
Replacement Part Description Part Number