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CooLift
®
REPLACING DIFFERENTIAL ASSEMBLY
TOOLS NEEDED: #2 AND #3 PHILLIPS SCREWDRIVER, 7/16” WRENCHES, 1/2” WRENCHES,
3/16 ALLEN WRENCH, 5/16 ALLEN WRENCH, BLUE THREAD LOCKER
1)
Place the CooLift on a level flooring surface with the holding brake engaged. Raise deck completely.
Turn off main
power switch.
Disconnect the batteries.
2)
You will need to remove the differential from the bottom of the CooLift. Place the CooLift safely on sturdy surfaces
that raise the CooLift at least 12” off the ground.
3) Remove the deck and the center brace.
4) Loosen the jam nut on the motor adjustment plate on both sides of the unit. Loosen the four hex head screws on the
LH side motor mount plate and the two hex head screws on the RH motor mount plate. Turn adjustment screw and
slide the motor forward slightly to loosen chain.
5) Loosen the four hex head screws from the clutch mounting plates on each side of the CooLift with 1/2” wrench.
Loosen the jam nut on clutch adjustment plate and turn the adjustment screws and slide the clutch toward the
differential slightly to loosen the chain to the differential. Make sure both chains are loose.
6) Loosen the two #10-32 screws and lock nuts found on the clutch anti-rotation bracket and top diagonal brace.
7) Remove clevis pin securing the clutch to the anti-rotation bracket.
8)
Remove the master link from then chain between the clutch and differential; remove the chain. Engage the CooLift
parking brake and remove the retaining lock nut for each wheel. Keep the nut for reassembly.
9) Release parking brake. Remove the brake calipers by removing the caliper mounting screws using a 5mm Allen
wrench. NOTE: Do not engage the brake lever while the brake calipers are off the cart.
10) Remove the wheels, making sure to keep the key and washer for reassembly.
11) Remove the four 1” long hex head screws (A) from diagonal top brace and remove (B).
12) Remove the four 1” long hex head screws (A) from lower brace and remove (C).
13)
Take out the four socket cap screws (F) and lock nuts (G) that fasten the differential mount assemblies (H) to the
reinforcement plate (E) (for both sides).
14)
Tip - this step is easier with two people - To remove differential from assembly, the reinforcement plates must be
moved inward to clear the frame side rail “lip.” Once plates are removed, the differential can drop from the CooLift
frame.
15)
Retain the differential mount assemblies and reinforcement plates.
16)
Remove the 4-1/4” long screws (H), hex lock nuts (J) and sprocket (I) from the differential. Reassemble the sprocket
and hardware to new differential.
17)
Slide the bearing mount plates over the new differential axle, taking care not to slide them in all the way down the
differential shaft. Try to keep them toward the outer edge of the shaft as you replace. Ensure they are in the same
orientation on the shaft as shown.
18)
Tip - this step is easier with two people - push the differential up into the CooLift frame and hold in place while you
replace the reinforcement plates. Make sure reinforcement plates are positioned on the side rail lip and are flat
against the side rail. When properly in position, the trans axle should be able to be rested on the enforcement plates.
19) Replace the four screws and lock nuts for the bearing mount plates and reinforcement plates, on both sides. Replace
the lower brace onto the frame; apply blue thread locker on screws before replacing.
20)
Reconnect the chain between the differential and clutch.
21) Replace the top diagonal brace to the frame; apply blue thread locker on screws before replacing.
22) Replace the wheel key into the axle (gently tap with hammer if needed); replace the wheel, washer and lock nut.
Tighten the lock nut until snug.
23) Replace the calipers; apply blue thread locker on screws before replacing. Tip: Put calipers in position; install the
screws and turn them snug still allowing the caliper assembly to move. Set and lock the brake - this will center the
caliper around the disk on the wheel. Then fully tighten the screws.
24) Turn the adjustment screws on the clutch adjustment plates so that the clutch chain has 1/4” of play when you push
on it. Make sure that the clutch adjustment plates are the same distance apart from the differential mount block.
Tighten the jam nut on the clutch adjustment plate (see page 29).
NOTE 1: Uneven tensioning of the chain between the clutch and motor will cause alignment issues. Misalignment
will cause: extra noise, chain wear, uneven sprocket wear, potential for the chain to come off sprocket, and potential
failure of the chain and/or sprocket.
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.
