Magliner Coolift CPA Series User manual

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CooLift®
Serial #: ________________________________
Date of Purchase: ________________________
Service Manual
IMPORTANT: Read entire manual before operating
For CooLift models with electric hydraulic lift AND propulsion
(CPA-- models)

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CooLift®
Table of Contents
CooLift Toolkit ........................................................................................................................................3
Vertical Loop Throttle Handle Removal ................................................................................................4
Vertical Loop Throttle Handle Replacement...................................................................................... 4-5
Replacing Throttle .................................................................................................................................6
Replacing Throttle Interlock Button .......................................................................................................7
Bulk Head Removal and Installation.................................................................................................8-11
Replacing Corner Post ........................................................................................................................12
Replacing Pallet Stops ........................................................................................................................12
Replacing Front Wheel........................................................................................................................13
Replacing Rear Swivel Caster.............................................................................................................13
Replacing Brushes ..............................................................................................................................14
Replacing Back Panel Latch................................................................................................................15
Removing Deck ...................................................................................................................................15
Removing Bottom Pans/Brace ............................................................................................................16
Replacing Containment Strap and Tongue..........................................................................................17
Replacing Battery Charger ..................................................................................................................18
Replacing Charger Cord................................................................................................................ 19-20
Replacing Power Switches..................................................................................................................21
Replacing Directional Switch...............................................................................................................21
Replacing Battery Meter......................................................................................................................22
Replacing Circuit Breaker....................................................................................................................23
Replacing Propulsion Controller..........................................................................................................24
Electrical Schematic ............................................................................................................................25
Replacing Motor Assembly ............................................................................................................ 26-27
Replacing Clutch Assembly ........................................................................................................... 28-29
Replacing Di󰀨erential Assembly .................................................................................................... 30-31
Changing Brake Caliper ................................................................................................................ 32-33
Changing Brake Pad ..................................................................................................................... 34-35
Changing Upper Brake Line .......................................................................................................... 36-37
Changing Lower Brake Line .......................................................................................................... 38-39
Replacing Brake Master Cylinder.................................................................................................. 40-41
Bleeding Brakes ............................................................................................................................ 42-43
Changing Hydraulic Pump............................................................................................................. 44-45
Changing Hydraulic Cylinder......................................................................................................... 46-47
Bleeding Hydraulic System............................................................................................................ 48-49
Replacing Brake Pawl ................................................................................................................... 50-51
Relocating Master Cylinder .................................................................................................................51
Replacing Center Wheel and Brake Disc ............................................................................................52
Troubleshooting............................................................................................................................. 53-54
Inspection / Maintenance Checklist................................................................................................ 55-62

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CooLift®
• Set of torx drivers
• #2, #3, #4 Phillips head screwdrivers
• 5/16”, 7/16”, two - 9/16”, 5/8”, 11/16”, 3/4”, 13/16” wrenches
• 6mm, two - 8mm, 10mm, 12mm, 13mm, 14mm, 17mm, two - 33mm,
35mm wrenches
• Four spacer blocks (4” x 4” x 24” wooden blocks)
• Isopropyl alcohol
• Vise on workbench
• Four vise-grip plier clamps (size 6r)
• Channel locks
• Rubber mallet
• Drift pin
• 1/2” socket w/extension and ratchet
• Needle nose pliers
• #1 at head screwdriver
• 4mm, 5mm Allen wrench
• 5/16”, 9/64” Allen wrench
• Tape measure
• Torque wrench
• Medium at head screwdriver
• Drip pan (cake pan will work)
• Absorbing material (kitty litter)
• DOT 3 or DOT 4 brake uid
• Hydraulic uid
• Shop towels
• Tube of clear silicone sealant
• Medium strength thread locker (blue)
• Flashlight
• Hydraulic thread sealant
• Utility knife
CooLift Toolkit

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CooLift®
VERTICAL LOOP THROTTLE HANDLE REMOVAL
TOOLS NEEDED:
TORX T30 DRIVER, #3 PHILLIPS SCREWDRIVER, 7/16” WRENCH, 7/64 ALLEN WRENCH
1) Turn o󰀨 main power switch. Disconnect the batteries.
2) Unplug the throttle and throttle interlock button wiring from the main wiring harness (see pages
6-7).
3) Remove the two socket head screws at the lower part of the handle using two 7/16” wrenches.
4) Remove the two pan head machine screws at the top of the handle using #3 Phillips and one 7/16
wrench.
5) Remove the pan head machine screw holding the horizontal brace to the vertical loops.
6) Rotate the vertical loop handle toward center to clear the upper handle mounts.
7) The handle should be able to slide vertically through the end of the horizontal brace and removed.
This may take some e󰀨ort and the end of the brace can be pried open slightly if necessary to ease
removal.
8) As the handle lifts, carefully guide and pull the throttle and throttle interlock cables through the
opening in the enclosure.
9) Once the cables have been pulled out of the enclosure the handle can be removed completely.
VERTICAL LOOP THROTTLE HANDLE REPLACEMENT
TOOLS NEEDED:
TORX T30 DRIVER, #3 PHILLIPS SCREWDRIVER, 7/16” WRENCH, , 7/64 ALLEN WRENCH
NOTE: Replacing a handle on the CooLift requires that the entire handle assembly rst must be
removed. See Vertical Loop Handle Removal for instructions.
1) Turn o󰀨 main power switch. Disconnect the batteries.
2) With the entire handle assembly removed from the CooLift, take the new vertical loop handle
and slide the replacement handle into the horizontal brace, before it is lowered into place take
the throttle and interlock cables and feed them into the opening of the enclosure. Slide the
replacement handle into place and replace the screw; nger tighten only for now.
3) As the handle is lowered into place carefully pull the cables into the enclosure being sure not to
pinch them under the handle.
4) Once the handle is seated down rotate the top of the vertical loop handle into position.
5) Place the two screws into the top holes in the handles and then hand tighten it to the frame.
6) Place the screws the bottom holes located in the handles and hand tighten them to each of the
corner posts.
7) Place the remaining screw in the hole that secures the horizontal brace to the vertical loop handle,
carefully being sure not to pinch the cables in the handle, and tighten them using #3 Phillips
screwdriver and 7/16” wrench.
8) Tighten all previously hand tightened screws.
9) Plug the throttle cable and the interlock cable back into the main wiring harness going to the
controller (see pages 6-7).

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CooLift®
Item Qty. Part Number
AVertical loop handle - RH (includes handle, throttle mount
weldment, throttle interlock button and cable) 1 309667
B Vertical loop handle - LH 1 309568
C Horizontal brace 1 309560
D Pan head machine screw - 1/4”-20 x 1-1/2” long 6 80105
E Hex lock nut 1/4”-20 10 80675
F Pan head machine screw - 1/4”-20 x 1-3/4” long 2 80106
G Brake master cylinder 1 309218
H Throttle 1 309782
I Hex head cap screw - 1/4”-20 x 3/4” long 2 80005
A
H
G
F
E
D
B
I

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CooLift®
REPLACING THROTTLE
TOOLS NEEDED: 33mm WRENCHES; 3mm ALLEN WRENCH
1) Place the CooLift on a level ooring surface with the holding brake engaged.
2) Turn o󰀨 main power switch. Remove back panel. Disconnect the batteries.
3) Unplug the throttle wiring harness from the main wiring harness that goes to the controller (see
below)
4) Using the Allen wrench remove the two screws from the top of the throttle mount.
5) Lift up on the tab and pull on the connector. Remove throttle cable.
6) Put new throttle on by pushing the cable into the new throttle until the plastic lock clicks.
7) Put two screws back into the top of the throttle with the lever towards the handle and snug up
the screws. Be careful not to tighten too much - over-torqueing may cause the lever to not move
freely. Tighten the screws and test to ensure that the throttle system is still moving freely.
8) Reconnect the throttle to the main wiring harness going to the controller and replace the back
panel.
A
Throttle mount screws
Unplug throttle from main
wiring harness HERE.
This part of the main wiring
harness consists of three
BLACK wires.
Item Qty. Part No.
A Throttle 1 309782

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CooLift®
REPLACING THROTTLE INTERLOCK BUTTON
TOOLS NEEDED: #3 PHILLIPS SCREWDRIVER, FLAT HEAD SCREWDRIVER, 7/16” WRENCH,
NEEDLE NOSE PLIERS
Item Qty. Part No.
AVertical handle assembly with throttle (includes
items below): 1 309667
B Handle 1 309627
C Mounting weldment for throttle 1 309765
D Pan head machine screw - 1/4”-20 x 1-3/4” long 1 80106
E Hex lock nut - 1/4”-20 1 80675
F Throttle interlock button 1 62042
G Cable for throttle interlock (in handle, not shown) 1 62057
H Throttle 1 309782
I Throttle cable (in handle, not shown) 1 62073
J Socket head cap screw - #10-24 x 1-1/2” long 2 80145
1) Place the CooLift on a level ooring surface with the holding brake engaged.
2) Turn o󰀨 main power switch. Remove back panel. Disconnect the batteries.
3) Unplug throttle interlock button wiring harness from the main wiring harness that goes to the
controller (see below).
4) Carefully pull old interlock button out of the handle being careful not to damage the wiring. Use
the at head screwdriver if necessary.
5) Remove wires from button.
6) Attach wires to the new button (quick connect tabs) by aligning the connector with tab and push
on. It does not matter which wire goes on which tab.
7) Carefully insert button into the hole in handle, and press in place.
8) Plug throttle interlock button wiring harness into the main wiring harness as shown below.
B
C
D
E
FH
J
Unplug throttle interlock
from main wiring harness
HERE.
This part of the main wiring
harness consists of two
RED wires.

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CooLift®
CPA43 BULK HEAD REMOVAL
TOOLS NEEDED:
7/16” WRENCH, 1/2” WRENCH, #3 PHILLIPS SCREWDRIVER, #4 PHILLIPS SCREWDRIVER
SPACER BLOCK (4” x 4” x 24” WOODEN BLOCK)
Note: It is important to keep the CooLift upright at all times.
1) Place the CooLift on a level ooring surface with the holding brake engaged.
2) Raise the deck to the highest position.
3) Place a spacer block between the deck and the base of the cart.
4) Turn o󰀨 main power switch.
5) Remove the two screws (I) that attach the bulk head (A) to the base plate using the #4 Phillips
screwdriver and the 1/2” wrench.
6) Take out the four screws (G) that attach the bulk head saddle plate (B) and the load retaining strap
assembly and spacer (C, D) to the bulk head and the main cart using the #3 Phillips screwdriver
and the 7/16” wrench.
NOTE: If the bulk head is going to be reinstalled after servicing, only the two screws (G)
anchored to the main cart and the saddle plate need to be removed. If the bulk head is
taken o󰀨 and the CooLift will be used in the 53” pallet conguration, a new saddle plate
(309151) will need to be installed.
7) Lift and remove the saddle plate. Then lift and remove the bulk head frame to disengage from the
base plate.
CPA43 BULK HEAD INSTALLATION
TOOLS NEEDED:
7/16” WRENCH, 1/2” WRENCH, #3 PHILLIPS SCREWDRIVER, #4 PHILLIPS SCREWDRIVER
SPACER BLOCK (4” x 4” x 24” WOODEN BLOCK)
Note: It is important to keep the CooLift upright at all times.
1) Place the CooLift on a level ooring surface with the holding brake engaged.
2) Raise the deck to the highest position.
3) Insert a spacer block between the deck and the base of the cart.
4) Turn o󰀨 main power switch.
5) Slide the bulk head (A) into position on the bulk head mounts located on the base plate.
6) Place the bulk head saddle plate (B) into position with the containment strap assembly and strap
spacer (C, D) above it and attach using the four screws (G) and lock nuts (H) and nger tighten.
7) Attach the bulk head to the mounts on the base plate using the two screws (I) and securely tighten
them to the lock nuts (J) using the #4 Phillips screwdriver and the 1/2” wrench.
8) Securely tighten the four screws (G) in the bulk head saddle plate (B) using the #3 Phillips
screwdriver and the 7/16” wrench.

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CooLift®
Item Qty. for
CTA43
Qty. for
CTA53 Part Number
A Bulk head for CTA43 1 -- 309790
B Bulk head saddle plate for CTA43 1 -- 309341
C Containment strap 1 1 309152
D Containment strap mounting spacer 1 1 309150
E Screw - 3/8”-16 x 1-1/2” long 1 1 79988
F Hex lock nut - 3/8”-16 1 1 80603
G Screw - 1/4”-20 x 2-3/4” long 4 2 80111
H Hex lock nut - 1/4”-20 4 2 80675
I Screw - 5/16”-18 x 1” long 2 -- 80313
J Hex lock nut - 5/16”-18 2 -- 80676
Completed assembly
E
C
D
B
F
G
A
H
J
I

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CooLift®
CPA48 BULK HEAD REMOVAL
TOOLS NEEDED:
7/16” WRENCH, 1/2” SOCKET END WRENCH, #3 PHILLIPS SCREWDRIVER, TWO 9/16”
WRENCHES, SPACER BLOCK (4” x 4” x 24” WOODEN BLOCK)
Note: It is important to keep the CooLift upright at all times.
1) Place the CooLift on a level ooring surface with the holding brake engaged.
2) Raise the deck to the highest position.
3) Place a spacer block between the deck and the base of the cart.
4) Turn o󰀨 main power switch.
5) Remove the two screws (I) and lock nuts (F) that attach the bulk head (A) to the base plate using
the 1/2” socket end wrench.
6) Take out the four screws (G) and lock nuts (H) that attach the bulk head saddle plate (B) and the
containment strap assembly and spacer (C, D) to the bulk head and the main cart using the #3
Phillips screwdriver and the 7/16” wrench.
NOTE: If the bulk head is going to be reinstalled after servicing, only the two screws (G)
anchored to the main cart and the saddle plate need to be removed. If the bulk head is
taken o󰀨 and the CooLift will be used in the 53” pallet conguration, a new saddle plate
(309151) will need to be installed.
7) Lift and remove the saddle plate. Then lift and remove the bulk head frame to disengage from the
base plate.
CPA48 BULK HEAD INSTALLATION
TOOLS NEEDED:
7/16” WRENCH, 1/2” SOCKET END WRENCH, #3 PHILLIPS SCREWDRIVER, TWO 9/16”
WRENCHES, SPACER BLOCK (4” x 4” x 24” WOODEN BLOCK)
Note: It is important to keep the CooLift upright at all times.
1) Place the CooLift on a level ooring surface with the holding brake engaged.
2) Turn o󰀨 main power switch.
3) Slide the bulk head (A) into position on the base plate in the location shown in Figure 2.
4) Fasten in place using the two screws (I) and lock nuts (F) and nger tighten (the screw heads will
be on top of the base plate and the lock nuts underneath).
5) Place the bulk head saddle plate (B) into position and attach using the four 1/4”-20 x 2-3/4” long
screws (G) and 1/4”-20 lock nuts (H) and nger tighten.
6) Place the containment strap mounting spacer (D) onto the bulk head saddle plate and then place
the containment strap assembly (C) onto the mounting spacer. Insert one 3/8”-16 x 1-1/2” long
screw (E) and 3/8”-16 lock nut (F) and securely tighten using the two 9/16” wrenches.
7) Once all items are in place, securely tighten the hardware for the bulk head saddle plate and for
the hardware connecting the bulk head to the base plate