1. Manuals
  2. Brands
  3. Magliner Manuals
  4. Outdoor Cart
  5. Coolift CPA Series
  6. Service manual

Magliner Coolift CPA Series Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

CooLift
®
Service Manual
For CooLift models with electric hydraulic lift AND propulsion
(CPA-- models)
IMPORTANT: Read entire manual before operating
Serial #: ________________________________
Date of Purchase: ________________________
1-800-MAGLINE (624-5463)
Page 1
www.magliner.com

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Coolift CPA Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Magliner Coolift CPA Series

Summary of Contents for Magliner Coolift CPA Series

  • Page 1 CooLift ® Service Manual For CooLift models with electric hydraulic lift AND propulsion (CPA-- models) IMPORTANT: Read entire manual before operating Serial #: ________________________________ Date of Purchase: ________________________ 1-800-MAGLINE (624-5463) Page 1 www.magliner.com...

  • Page 2: Table Of Contents

    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 1-800-MAGLINE (624-5463) Page 2 www.magliner.com...

  • Page 3: Coolift Toolkit

    • DOT 3 or DOT 4 brake fluid • Hydraulic fluid • Shop towels • Tube of clear silicone sealant • Medium strength thread locker (blue) • Flashlight • Hydraulic thread sealant • Utility knife 1-800-MAGLINE (624-5463) Page 3 www.magliner.com...

  • Page 4: Vertical Loop Throttle Handle Removal

    #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). 1-800-MAGLINE (624-5463) Page 4 www.magliner.com...
  • Page 5 E Hex lock nut 1/4”-20 80675 F Pan head machine screw - 1/4”-20 x 1-3/4” long 80106 G Brake master cylinder 309218 H Throttle 309782 I Hex head cap screw - 1/4”-20 x 3/4” long 80005 1-800-MAGLINE (624-5463) Page 5 www.magliner.com...

  • Page 6: Replacing Throttle

    8) Reconnect the throttle to the main wiring harness going to the controller and replace the back panel. Throttle mount screws Item Qty. Part No. A Throttle 309782 Unplug throttle from main wiring harness HERE. This part of the main wiring harness consists of three BLACK wires. 1-800-MAGLINE (624-5463) Page 6 www.magliner.com...

  • Page 7: Replacing Throttle Interlock Button

    Hex lock nut - 1/4”-20 80675 Throttle interlock button 62042 Cable for throttle interlock (in handle, not shown) 62057 Throttle 309782 Throttle cable (in handle, not shown) 62073 Socket head cap screw - #10-24 x 1-1/2” long 80145 1-800-MAGLINE (624-5463) Page 7 www.magliner.com...

  • Page 8: Bulk Head Removal And Installation

    (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. 1-800-MAGLINE (624-5463) Page 8 www.magliner.com...
  • Page 9 F Hex lock nut - 3/8”-16 80603 G Screw - 1/4”-20 x 2-3/4” long 80111 H Hex lock nut - 1/4”-20 80675 Screw - 5/16”-18 x 1” long 80313 J Hex lock nut - 5/16”-18 80676 Completed assembly 1-800-MAGLINE (624-5463) Page 9 www.magliner.com...
  • Page 10 (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 1-800-MAGLINE (624-5463) Page 10 www.magliner.com...
  • Page 11 E Screw - 3/8”-16 x 1-1/2” long 79988 F Hex lock nut - 3/8”-16 80603 G Screw - 1/4”-20 x 2-3/4” long 80111 H Hex lock nut - 1/4”-20 80675 Screw - 3/8”-16 x 1-1/4” long 80026 Figure 2 1-800-MAGLINE (624-5463) Page 11 www.magliner.com...

  • Page 12: Replacing Corner Post

    A Screw - 5/16”-18 x 1-1/4” long 80012 Pallet stop - CPA43 models 309826 Pallet stop - CPA48 models 309206 C Hex lock nut - 5/16”-18 80676 Quantities listed are for both sides of the CooLift CTA43 CTA48 309826 309206 1-800-MAGLINE (624-5463) Page 12 www.magliner.com...

  • Page 13: Replacing Front Wheel

    Hex head cap screw - 3/8”-16 80026 x 1-1/4” long Hex lock nut flange - 3/8”-16 80624 Caster assembly - 6” x 2” 130066 swivel grey flat tread Quantities listed are for each rear swivel caster 1-800-MAGLINE (624-5463) Page 13 www.magliner.com...

  • Page 14: Replacing Brushes

    8) Using the pliers, re-crimp the ends of the slots to enable the brush sections to remain in place. 9) Place the back access panel back into position and secure with the latches. Item Qty Part Number A Yoke brush 309257 B Back panel brush 309259 1-800-MAGLINE (624-5463) Page 14 www.magliner.com...

  • Page 15: Replacing Back Panel Latch

    Part Number A Deck 309825 B Flat head machine screw - 1/4” -20 x 2” long 80224 C Hex lock nut - 1/4”-20 80675 D Slotted truss head screw - 3/8”-16 x 1/2” long 80286 1-800-MAGLINE (624-5463) Page 15 www.magliner.com...

  • Page 16: Removing Bottom Pans/Brace

    309821 B Center brace 309614 C Rear pan 309822 D Pan head thread forming screw - 1/4”-20 x 3/4” long 80308 Hex head cap screw with thread locking patch - 80010 5/16”-18 x 3/4” long 1-800-MAGLINE (624-5463) Page 16 www.magliner.com...

  • Page 17: Replacing Containment Strap And Tongue

    (J) and lock nut (H), allowing the tongue to rotate freely. Front Underside Part View Item Qty. Number Hex lock nut w/ nylon insert - 80683 #10-24 UNC Containment strap tongue 309133 Screw - #10-24 x 2-1/2” long 80004 1-800-MAGLINE (624-5463) Page 17 www.magliner.com...

  • Page 18: Replacing Battery Charger

    14) Replace the back access panel. ON/OFF switch Figure 3 Item Description Qty. Part # Charger connect cable 62046 AC charger for 24v battery 63004A Pan head machine screw - #10-32 x 80121 3/4” long Charger mounting bracket 309207 1-800-MAGLINE (624-5463) Page 18 www.magliner.com...

  • Page 19: Replacing Charger Cord

    8) To store the charger cord, coil the charger cord around the two brackets, interlacing the cord plug within the coiled cord loops to secure it. Figure 2 shows the completed bracket assembly with the cord properly secured to the brackets. 1-800-MAGLINE (624-5463) Page 19 www.magliner.com...
  • Page 20 Description Qty. Part # Cord grip - PG-16 309122 Hex lock nut - PG-16 309123 Electrical cord 8’ long with C13 connector on one end 64020 Plug - 15A rated 5-15p three-prong cord plug 61053 1-800-MAGLINE (624-5463) Page 20 www.magliner.com...

  • Page 21: Replacing Power Switches

    14mm wrench. 7) Recheck all connections for correct wiring placement and tightness. Reconnect the batteries. Part Item Qty. Number A Main power on/off switch 62016 B Propulsion power on/off switch 62038 C Propulsion directional switch 62080 1-800-MAGLINE (624-5463) Page 21 www.magliner.com...

  • Page 22: Replacing Battery Meter

    (see Figure 3). 13) Recheck all connections for correct wiring placement and tightness Press tabs inward Figure 1 Figure 3 Figure 2 Description Qty. Part Number Battery charge meter 62033 1-800-MAGLINE (624-5463) Page 22 www.magliner.com...

  • Page 23: Replacing Circuit Breaker

    6) Hold the replacement circuit breaker in place on the enclosure shelf and tighten the hex nut on the outside with the 17mm wrench. 7) Recheck all connections for correct wiring placement and tightness. Reconnect the batteries. Part Item Number Circuit breaker 62037 Hex nut 1-800-MAGLINE (624-5463) Page 23 www.magliner.com...

  • Page 24: Replacing Propulsion Controller

    Attach black wire Motor connector Attach wire marked “+” Description Part No. Clutch connector Propulsion controller 63033 Wiring harness for propulsion power 64026 Main wiring harness 62054 Wiring harness for clutch connector 62053 Main wiring harness (C) 1-800-MAGLINE (624-5463) Page 24 www.magliner.com...

  • Page 25: Electrical Schematic

    CooLift ® FULL ELECTRICAL SCHEMATIC 1-800-MAGLINE (624-5463) Page 25 www.magliner.com...

  • Page 26: Replacing Motor Assembly

    18) Replace the deck and bottom pan (use blue thread locker on the screws for bottom pan). Plug the motor into the controller. Reconnect the batteries. 19) Turn on the unit. Carefully test propulsion to make sure it drives in the intended direction. 1-800-MAGLINE (624-5463) Page 26 www.magliner.com...
  • Page 27 Socket head cap screw - 5/16”-18 x 3” long 80126 Hex head cap screw - 5/16”-18 x 1” long 80011 Hex head cap screw - 5/16”-18 x 2” long 80015 Motor spacer plate 309808 Motor assembly 309837 1-800-MAGLINE (624-5463) Page 27 www.magliner.com...

  • Page 28: Replacing Clutch Assembly

    20) Tighten the jam nut on the motor adjustment plate. Fully tighten the four hex head screws on the LH side motor mount plate and the two hex head screws on the RH motor mount plate. 21) Replace the deck and bottom pan. Plug the clutch into the controller. Reconnect the batteries. 1-800-MAGLINE (624-5463) Page 28 www.magliner.com...
  • Page 29 Clevis pin - 3/16” diameter x 1” long 81093 Cotter pin - 1/16” x 3/4” long 81071 Clutch bearing mount plate - RH 309835 Clutch bearing mount plate - LH 309836 Clutch assembly 309676 Clutch adjustment plate 1-800-MAGLINE (624-5463) Page 29 www.magliner.com...

  • Page 30: Replacing Differential Assembly

    NOTE 2: Over-tensioning of the chain (even if tensioned evenly on both sides) can also cause issues. Over tensioning will cause the chain to stretch faster, leading to shorter chain and/or sprocket life. 1-800-MAGLINE (624-5463) Page 30 www.magliner.com...
  • Page 31 1-1/4” long Hex lock nut - 3/8”-16 80603 Differential mount assembly 309681 Hex head cap screw - 5/16”-18 80134 x 4-1/4” long Differential drive sprocket 309442 Hex lock nut with flange - 80627 5/16”-18 1-800-MAGLINE (624-5463) Page 31 www.magliner.com...

  • Page 32: Changing Brake Caliper

    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 1-800-MAGLINE (624-5463) Page 32 www.magliner.com...
  • Page 33 C Brake disc 309050 D Caliper assembly 309595 Caliper brake line assembly (includes F, G 309145 and H) Banjo bolt 80135 O-rings Banjo fitting on brake line Quantities listed are for one side of the CooLift 1-800-MAGLINE (624-5463) Page 33 www.magliner.com...

  • Page 34: Changing Brake Pad

    This will give you more room to fit in the new pads. Walk the piston back and forth until the piston is all the way back in the bore. Do the same thing on the other side. NOTE: Do not push the edge of the piston as they may crack or chip. 1-800-MAGLINE (624-5463) Page 34 www.magliner.com...
  • Page 35 Inserting the pads Item Qty. Part Number A Hex socket head cap screw - M6 x 20mm 80003 B Pair of brake pads 309594 C Caliper assembly 309595 Quantities listed are for one side of the CooLift 1-800-MAGLINE (624-5463) Page 35 www.magliner.com...

  • Page 36: Changing Upper Brake Line

    (H) and tighten with the 12mm wrench. 14) Connect the other end to the master cylinder in the same manner. 15) Bleed the brake system (see Bleeding the Brakes). 16) Reinstall the battery box (see Replacing Battery Box). 1-800-MAGLINE (624-5463) Page 36 www.magliner.com...
  • Page 37 A Master cylinder 309218 Cord grip - PG-21 309124 C Hex lock nut - PG-21 309125 D Master cylinder brake line 309083 Junction block 309051 Copper washer 80712 G Banjo bolt 80124 H Banjo fitting 1-800-MAGLINE (624-5463) Page 37 www.magliner.com...

  • Page 38: Changing Lower Brake Line

    10) Connect the new brake line (B) to the junction block (F) using the 8mm wrench and reroute it through in the same locations as the line to be replaced. 11) Bleed the brake system (see Bleeding the Brakes). 12) Reinstall the battery box (see Replacing Battery Box). 1-800-MAGLINE (624-5463) Page 38 www.magliner.com...
  • Page 39 6) Return brake line to inside of clip. Push the longer side of the clip top down towards the brake line to close the clip. Open position Closed position Item Qty. Part Number Brake line clip 61019 1-800-MAGLINE (624-5463) Page 39 www.magliner.com...

  • Page 40: Replacing Brake Master Cylinder

    10) Check the brake system for proper functioning. 11) If the system seems to be squishy or not functioning properly there may be some air trapped in the lines and they will need to be bled (see Bleeding the Brakes). 1-800-MAGLINE (624-5463) Page 40 www.magliner.com...
  • Page 41 F Master cylinder brake line (includes G) 309083 G Banjo fitting Quantities listed are for quantities shown - 2 additional 80712 and 1 additional 80124 are used at the lower end of the master cylinder brake line 1-800-MAGLINE (624-5463) Page 41 www.magliner.com...

  • Page 42: Bleeding Brakes

    T10 torx driver until fluid is noticed seeping out of the bleed screw. NOTE: It is not necessary to take the bleed screw out entirely, it just needs to be loosened a few turns to allow the air in the brake line to 1-800-MAGLINE (624-5463) Page 42 www.magliner.com...
  • Page 43 - an additional 80124 is Caliper bleed screw 80135 used at the top of the master Junction block 309051 cylinder line assembly Master cylinder brake line 309083 Banjo bolt 80124 Caliper brake line assembly 309145 1-800-MAGLINE (624-5463) Page 43 www.magliner.com...

  • Page 44: Changing Hydraulic Pump

    11) Reconnect each wiring harness (B) to pump connections using the 10mm and 13mm wrenches. 12) Reinstall the batteries. 13) The hydraulic system should be purged of all air within the system (see Bleeding the Hydraulic System). 1-800-MAGLINE (624-5463) Page 44 www.magliner.com...
  • Page 45 Pan head machine screw - 1/4”-20 x 3/4” long Figure 3 w/ locking patch (visible when batteries are 80257 removed) Manual pump handle 63014 Hydraulic pump reservoir 59501 Pump starter - 24v DC (solenoid) 63015 1-800-MAGLINE (624-5463) Page 45 www.magliner.com...

  • Page 46: Changing Hydraulic Cylinder

    14. Pour hydraulic fluid from old cylinders into the pump reservoir. 15. Turn on the power switch. 16. Elevate the cylinders to maximum height using the electric pump. Make certain the cylinder top fits properly in the mounting bracket in the CooLift deck. 1-800-MAGLINE (624-5463) Page 46 www.magliner.com...
  • Page 47 55403 Cylinder assembly (includes 55419 fitting, 59006 80396 screw and 80754 washer) F Fitting - NPT to flare 55401 Cylinder mount screw (not shown) 80010 Note: 55419 fitting compatible with cylinders manufactured 2017 and later. 1-800-MAGLINE (624-5463) Page 47 www.magliner.com...

  • Page 48: Bleeding Hydraulic System

    8) Using the 3/16” or 9/64” Allen wrench, loosen the bleed screw on the front cylinder by three complete revolutions. • For Rev H cylinders, loosen the bleed screw 1/4 turn. • For all other cylinders, loosen the bleed screw by three complete revolutions. 1-800-MAGLINE (624-5463) Page 48 www.magliner.com...
  • Page 49 Slotted truss head screw 3/8”-16 X 3/4” 80396 Helical lock washer 3/8” dia x 1/8” thick 80754 Hydraulic fluid 55407 Hydraulic fluid additive 2 oz. 55418 (Fill to 1/2 inch below the top when the deck is at the lowest position) 1-800-MAGLINE (624-5463) Page 49 www.magliner.com...

  • Page 50: Replacing Brake Pawl

    Pan head machine screw - #10-32 UNF x 1” long 80123 Flat washer for #10 screw 80763 Hex lock nut 10-32UNF thread 80684 Round head machine screw - #10-32 UNF x 7/8” long 80122 Lock washer split for #10 screw 80747 Cable tie 61052 1-800-MAGLINE (624-5463) Page 50 www.magliner.com...

  • Page 51: Relocating Master Cylinder

    4) The master cylinder can now be slid into another location. NOTE: Keep the master cylinder upright during this process to keep from introducing air into the brake system. 5) Tighten the screws to secure the master cylinder in the new location. FASTENING SCREWS JAM NUT 1-800-MAGLINE (624-5463) Page 51 www.magliner.com...

  • Page 52: Replacing Center Wheel And Brake Disc

    Brake disc for center wheel 309050 Pan head machine screw - 80246 #10-24 UNF x 3/8” long Flat washer - 3/4” 80706 Hex lock nut - 3/4”-16 80628 Wheel key - 6mm x 30mm 309626 1-800-MAGLINE (624-5463) Page 52 www.magliner.com...

  • Page 53: Troubleshooting

     Is there any foreign matter in the linkage system?  Check for loose wire connections.  Use the manual pump handle to lower the deck (the manual pump handle is stored inside the enclosure) 1-800-MAGLINE (624-5463) Page 53 www.magliner.com...
  • Page 54  Has the parking brake been released?  Check for loose wire connections from the controller or battery.  Is there any debris in the chains or in other parts of the propulsion system?  Contact Magline if problem persists. 1-800-MAGLINE (624-5463) Page 54 www.magliner.com...

  • Page 55: Inspection / Maintenance Checklist

    CooLift ® 1-800-MAGLINE (624-5463) Page 55 www.magliner.com...
  • Page 56 CooLift ® 1-800-MAGLINE (624-5463) Page 56 www.magliner.com...
  • Page 57 CooLift ® 1-800-MAGLINE (624-5463) Page 57 www.magliner.com...
  • Page 58 CooLift ® 1-800-MAGLINE (624-5463) Page 58 www.magliner.com...
  • Page 59 CooLift ® 1-800-MAGLINE (624-5463) Page 59 www.magliner.com...
  • Page 60 CooLift ® 1-800-MAGLINE (624-5463) Page 60 www.magliner.com...
  • Page 61 CooLift ® 1-800-MAGLINE (624-5463) Page 61 www.magliner.com...
  • Page 62 CooLift ® 1-800-MAGLINE (624-5463) Page 62 www.magliner.com...
  • Page 63 CooLift ® 1-800-MAGLINE (624-5463) Page 63 www.magliner.com...
  • Page 64 CooLift ® MAGLINE INC. ® Standish, Michigan 48658 1-800-MAGLINE (624-5463) www.magliner.com Form # B9364 REV November, 2019 CooLift is a registered trademark owned by ® © Copyright 2015-2019, Magline, Inc. Swift Water Logistics Patent: www.magliner.com/patents 1-800-MAGLINE (624-5463) Page 64 www.magliner.com...

This manual is also suitable for:

Coolift cpa 48Coolift cpa43

Table of Contents