Magliner CooLift CTA43, Service Manual

Page 1: ...1 800 MAGLINE 624 5463 Page 1 www magliner com CooLift Serial ________________________________ Date of Purchase ________________________ Service Manual IMPORTANT Read entire manual before operating...

Page 2: ...Battery Cells 18 19 Replacing Deck Positioning Up Down Switch 20 21 Replacing Battery Charger 22 24 Replacing Foam Mounting Strips 25 Replacing Battery Meter 26 Replacing Power Switch or Circuit Brea...

Page 3: ...our vise grip plier clamps size 6r Channel locks Rubber mallet Drift pin 1 2 socket w extension and ratchet Needle nose pliers 1 flat head screwdriver 4mm 5mm Allen wrench 5 16 9 64 Allen wrench Tape...

Page 4: ...CooLift requires that the entire handle assembly first must be removed See Vertical Loop Handle Removal for instructions 1 With the entire handle assembly removed from the CooLift slide the vertical l...

Page 5: ...head machine screw 1 4 20 x 1 3 4 long 2 80106 G Hex lock nut 1 4 20 10 80675 H Handle mount bracket 2 302721 I Pan head machine screw 1 4 20 x 1 1 2 long 4 80105 J Brake master cylinder 1 309218 K P...

Page 6: ...ft will be used in the 53 pallet configuration 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 bas...

Page 7: ...e 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 lo...

Page 8: ...late 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 CTA48 BULK HEAD INSTALLATION TOOLS NEEDED 7 16 WRENCH...

Page 9: ...A Bulk head for CTA48 1 309332 B Bulk head saddle plate for CTA48 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 loc...

Page 10: ...lock nut 5 16 18 3 80676 E Screw 5 16 18 x 1 1 2 long 2 80115 Quantities listed are for one side of the CooLift B A C E D REPLACING FOAM HANDLE SLEEVE ITEMS NEEDED ISOPROPYL ALCOHOL VISE Note It is im...

Page 11: ...e of the pallet stop as shown in Figure 1 and insert the screw A 5 Locate the front hole on the deck for CTA43 models or the back hole on the deck for CTA48 models as shown in Figure 2 Insert the pall...

Page 12: ...the 3 Phillips head screwdriver and the 1 2 wrench on the bottom two screws C on each side 8 Grasp the vertical handle mount assembly A to be replaced and lift it straight up to remove it from the ca...

Page 13: ...flat head screwdriver into end of the slotted frame that holds the brush section and bend the end of the slot open enough to allow the old sections to slide out A 6 Remove the old brush sections using...

Page 14: ...riage nut E using the two 1 2 wrenches 4 Remove the four carriage bolts D through the bottom of the caster yoke B Replacement 1 With the cart sitting on a level flooring surface and the holding brake...

Page 15: ...aster assembly can now be lowered and slid out of position Replacement 1 With the cart sitting on a level flooring surface the holding brake engaged and the rear access panel removed position the repl...

Page 16: ...nut H allowing the tongue to rotate freely REPLACING CONTAINMENT STRAP TOOLS NEEDED TWO 1 2 WRENCHES Note It is important to keep the CooLift upright at all times 1 Place the CooLift on a level floori...

Page 17: ...the floor Hold the handle E firmly with one hand grasp the red handled loop connected to the wiring harness D with the other hand and pull in an upward motion to disconnect the battery box C from the...

Page 18: ...t is a good practice to remove the black wire D in the wiring harness connected to the positive terminal on the top battery first 6 Remove the wires connecting both terminals of the defective battery...

Page 19: ...1 800 MAGLINE 624 5463 Page 19 www magliner com CooLift CHARGING PORT TOP BATTERY BOTTOM BATTERY D E F top battery cell F bottom battery cell G...

Page 20: ...s that mount the up down switch to the cabinet NOTE Do not try to remove the screws entirely from the switch box just hold the screws in place and remove the nuts 11 Feed the disconnected wires throug...

Page 21: ...1 800 MAGLINE 624 5463 Page 21 www magliner com CooLift A B C E D H F G Green wire to pump valve coil Black wire to solenoid battery post White wire to solenoid start post...

Page 22: ...ed If replacements are needed please see Replacing Foam Mounting Strips 9 Remove the battery charger from the mounting bracket D 10 Place the charger ON OFF switch on the ON position on the new charge...

Page 23: ...inside of the enclosure until a length of 6 1 2 to 7 is left iv Tighten the jam nut b Assemble cord plug see wiring part diagram next page i Shorten the three exposed wires to 7 8 1 long then strip e...

Page 24: ...indicator lights Troubleshooting tips if no light turns on Confirm 115v outlet is operable Confirm the charger ON OFF switch is in the ON position Confirm the input power cord is securely plugged into...

Page 25: ...charger and bracket from enclosure and set aside 6 Using a sharp tool cut or scrape off the existing foam strips from the underside of the enclosure box 7 The location for foam strips is 1 2 3 4 from...

Page 26: ...l of the battery meter and ensure the wire end does not fall back through the hole of the enclosure 8 Disconnect the white wire from the KEYSWITCH terminal of the battery meter and ensure the wire end...

Page 27: ...G POWER SWITCH TOOLS NEEDED 3 PHILLIPS SCREWDRIVER 14mm WRENCH 1 Place the CooLift on a level flooring surface and engage the holding brake 2 Turn off main power switch 3 Remove battery see Replacing...

Page 28: ...electrical connections see page 29 for detailed views 6 Recheck all connections for correct wiring placement and tightness 7 Reinstall the battery box see Replacing Battery Box for proper installation...

Page 29: ...power cord black wire G Charger port black wire F Pump black wire E Pump red wire J Battery box power cord red wire I Charger port red wire H Circuit breaker ON OFF Power switch K Circuit breaker wir...

Page 30: ...the wheels E off each end of the axle taking care to set them down on the side opposite the brake disc to prevent damage to the disc G 9 Loosen the four axle retaining screws C two on each side locate...

Page 31: ...20 B Clamp block for axle 1 309022 C Hex socket head cap screw 5 16 18 x 1 long 2 80038 D Straight cotter pin 1 81142 E Center wheel 10 x 2 with bearings 1 309059 F Washer 1 80718 G Brake disc 1 30905...

Page 32: ...he 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...

Page 33: ...D orientation to the brake disc C Then the screws may be tightened using the 5mm Allen wrench 17 Bleed the brake system see Bleeding the Brakes Quantities listed are for one side of the CooLift Compr...

Page 34: ...til fully extended 4 Position a spacer block between the deck and the base of the cart 5 Turn off the main power switch 6 Remove the brake caliper C by removing the caliper mounting screws A using a 5...

Page 35: ...lbs 16 Position the caliper C within the caliper mount and lightly hand tighten the mounting screws A Figure 4 NOTE Do not use the wrench on them until the caliper has been aligned or damage to the br...

Page 36: ...ush washers F using the 12mm wrench Drain as much brake fluid as possible into the drip pan NOTE Do not engage the brake lever while the brake line is removed 6 Remove the brake line D from the master...

Page 37: ...B C D F G E F G H H Item Qty Part Number A Master cylinder 1 309218 B Cord grip PG 21 1 309124 C Hex lock nut PG 21 1 309125 D Master cylinder brake line 1 309083 E Junction block 1 309051 F Copper wa...

Page 38: ...lock between the deck and the base of the cart 4 Turn off main power switch 5 Remove the battery see Replacing Battery Box 6 Position the drip pan below the caliper A and remove the banjo bolt D using...

Page 39: ...nd firmly pull towards the inside of the deck to remove the clip 5 Align a new brake clip so that the point of the brake clip will enter the frame from the inside of the unit and push the clip to snap...

Page 40: ...ile the reservoir cover is off because it may introduce air into the system 4 Position the new master cylinder A in place on the horizontal grip and tighten into place using the T30 wrench 5 Take the...

Page 41: ...1 309218 B Cover screws n a C Reservoir cover n a D Copper washer 2 80712 E Banjo bolt 1 80124 F Master cylinder brake line includes G 1 309083 G Banjo fitting n a G B C Quantities listed are for qua...

Page 42: ...of the master cylinder A to keep fluid from splashing out but do not tighten the screws 9 Pump the brake handle eight to ten times and note the amount of pressure it takes each time If the amount of p...

Page 43: ...and refill the reservoir if necessary after every other cycle 16 Repeat the previous three steps on the right side caliper of the cart then repeat these same steps for the left side caliper Keep repea...

Page 44: ...as much of the hydraulic fluid as possible into the drip pan 6 Remove the three screws F that hold the pump mount plate C to the vertical slides using the 3 Phillips head screwdriver NOTE Take care t...

Page 45: ...r to pump 1 62022 C Pump mount plate 1 309062 D Pump assembly includes items all pictured in Figure 3 1 63013 E Flat head machine screw 5 16 18 x 3 4 long 3 80261 F Pan head machine screw 1 4 20 x 3 4...

Page 46: ...for reuse 3 Block the lift platform with two 2 x 4 wooden spacer blocks on edge 4 Lower the cylinders completely using the electric pump 5 Turn off the power switch 6 Loosen the hydraulic fittings fr...

Page 47: ...o front cylinder 1 55410 B Line tee to rear cylinder 1 55411 C Line tee to coupling 1 55412 D Line coupling to bulk head 1 55409 E 90 degree bulk head fitting 1 55400 F Hose pump to bulk head fitting...

Page 48: ...number and rev level on the cylinder body above the port 1 Place the CooLift on a level flooring surface with the holding brake engaged 2 Turn off main power switch 3 Remove the back access panel fro...

Page 49: ...the air is out of the system usually 2 or 3 repetitions are all that is needed 14 Once the cylinders have been bled fully raise the cylinders The center section of the rod end should be flush with the...

Page 50: ...k of the spring as it will be used within the new assembly 3 Place the spring inside the new pawl B as illustrated in Figure 3 and slide it in place over the end of the brake lever and secure with the...

Page 51: ...ure it is working properly A RELOCATING MASTER CYLINDER TOOLS NEEDED TORX T30 WRENCH Note It is important to keep the CooLift upright at all times 1 Place the CooLift on a level flooring surface 2 Loo...

Page 52: ...ning the manual release valve Do you see any fluid leaking out of the gas springs The deck lifts slower than usual Is the manual release valve closed all the way Is the fluid level correct in the rese...

Page 53: ...or 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...

Page 54: ...r 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 lowe...

Page 55: ...048 Hydraulic cylinder assembly includes hydraulic cylinder with fitting 80396 screw and 80754 washer 59006 Hydraulic fluid 32oz container 55407 Hydraulic fluid additive 32 oz container 55418 Hydrauli...

Page 56: ...late 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 m...

Page 57: ...g No squeaks or groans from cylinders Manual bypass valve should not leak Method of Inspection Visual inspection Visual inspection Push cart and let roll Roll cart at walking speed and apply brakes Lo...

Page 58: ...in good condition No damage No excessive wear Visual inspection Straight sections Smooth curves Flat surfaces Minor scratches and dings Weekly Deck Yoke screws are not loose in deck Manual inspection...

Page 59: ...xle plating is not cracked or damaged Weekly Operator Interface External mounting screws are tight Base plate mounting to frame Enclosure mounting or base plate Handle mounting screws Switch plate mou...

Page 60: ...dry Monthly Hydraulics No cracks or damage to hose or tubing Visual inspection No deep scratches or dents Monthly Hydraulics Manual operation Operate hydraulic pump up and down several times manually...

Page 61: ...ht with no signs of damage or wear Minimal play between pins and links Bushings are flush with side of the links Monthly Linkage System Link pins are not loose in deck frame or sync links Manual inspe...

Page 62: ...l times Blocks are not damaged or worn and move freely in the vertical slide Quarterly Operator Interface Gas spring mounting Mounting studs Rod and body connectors Preload screws are tight Manual Vis...

Page 63: ...ass or Fail Timing Notes Operator Interface Gas spring condition and operation Visual inspection Disconnect cylinders from studs per instructions in manual and try to compress the spring Rods should b...

Page 64: ...r com CooLift MAGLINE INC Standish Michigan 48658 1 800 MAGLINE 624 5463 www magliner com Form B9243 May 2018 REV Copyright 2009 2018 Magline Inc Patent www magliner com patents CooLift is a registere...