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CooLift
®
CHANGING BRAKE CALIPER
TOOLS NEEDED:
THREE SPACER BLOCKS (4” x 4” x 24” WOODEN BLOCKS)
2.5mm ALLEN WRENCH
5mm ALLEN WRENCH
8mm WRENCH
TORQUE WRENCH
MEDIUM FLAT HEAD SCREWDRIVER
DRIP PAN
ABSORBING MATERIAL (for containing spills)
ISOPROPYL ALCOHOL
Note: It is important to keep the CooLift upright at all times.
CAUTION:
DOT 4 and DOT 5 brake fluids are a slip hazard on any flooring surface.
Brake fluid will strip paint; any spills on a painted surface should be wiped up and
rinsed with isopropyl alcohol immediately.
Brake fluid can be an irritant to human tissue and should be washed off in flowing
water.
If brake fluid is exposed to the eye, flush immediately and continuously for 15
minutes.
1) Place the CooLift on a pair of spacer blocks positioned on each side of the center wheel such that
the front most block is directly under the front hydraulic cylinder and the rear most block is directly
under the rear hydraulic cylinder.
2) Disengage the holding brake.
3) Raise the deck by pressing the up switch until fully extended.
4) Position a spacer block between the deck and the base of the cart.
5)
Turn off main power switch.
6) Remove the brake caliper (D) by removing the caliper mounting screws (A) using a 5mm Allen
wrench. NOTE: Do not engage the brake lever while the brake calipers (D) are off the cart (Figure
1).
7)
Place the large flat head screwdriver between the brake pads (B) on the caliper (D) and rotate it
to compress the piston position and force as much brake fluid as possible back into the brake fluid
reservoir (Figure 2).
8) Remove the brake pads and leaf spring from the caliper (Figure 3).
9) Position the caliper (D) directly over the drip pan and remove the banjo bolt (F) using the 8mm
wrench to disconnect the brake line.
10) Install the brake line (E) to the new caliper (D) making sure to utilize an O-ring (G) on each side of
the banjo fitting (H) and tighten to 60 +/- 5 in/pounds of torque (Figure 4).
11)
Wipe up any brake fluid that has leaked on the caliper (D).
12) Pinch the brake pad tabs together so that the pad material on both pads are touching.
13) Slide brake pads into the top window of the caliper until they come to a stop (see Figure 3).
14) Using a 2.5mm Allen wrench install and tighten the pad retaining pin. Pad pin torque should be 10
