Pelican
™
Elite Coolers
Replacement Parts Instructions
SECTION A: REPLACING THE LATCH
Models: This procedure is applicable to Pelican
™
Elite Cooler models
45QW, 55QW, 80QT, 95QT, 150QT, 250QT
Required Tools:
» Phillips head or #20 Torx bit driver
1.
Lay the cooler flat on a worktable.
2.
Remove the four installation screws
from the damaged latch.
3.
When the vent is present under the
latch, ensure that it is clear of any
debris before installing the new latch.
4.
Obtain the replacement latch. Install
the four #10-24 x ½" screws through
the replacement latch and into the
T-nuts in the cooler molding.
NOTE: When a vent is present
under the latch, place the rubber
washer into the recess in the
underside of the latch before
installing.
5.
To replace the bottom portion of
the latch, remove the four screws
and obtain the replacement strike.
NOTE: Bottom portion may not
need to be replaced if it is not
broken.
6.
Install the two bottom screws into
T-nuts loosely. Check the latch/
strike fit by closing the latches onto
the strikes. Check that the latch
closes without having to be forced
and that it releases with ease. Adjust
alignment if necessary. Finally, install
and tighten the remaining screws.
SECTION B: REPLACING THE LATCH
Models: This procedure is applicable to Pelican
™
Elite Cooler models 20QT, 30QT, 45QW,
50QT, 55QW, 70QT, 80QT, 95QT
Required Tools:
» Hammer
» Vice grips
» Punzón botador de 3/16"
1.
Lay the cooler flat on a worktable.
2.
To remove the old latch, align the
pin punch with the latch pin.
3.
From the center of the cooler
outwards, use the hammer to gently
tap on the pin punch. Continue tapping until the opposite
end of the latch pin pops out.
4.
Clamp the end of the pin with a pair of vice grips.
5.
Tap the vice grips using the hammer until the
pin is entirely removed from the cooler.
6.
To replace the old latch with a new latch, align the new
latch with the installation holes. From the outer edge of
the cooler inwards, drive the latch pin into the channel
with the hammer until the pin is flush on both ends.
7.
To replace the bottom portion of the
latch, remove the four screws and
obtain the replacement strike.
NOTE: Bottom portion may
not need to be replaced if it is
not broken.
8.
Install the two bottom screws into
T-nuts loosely. Check the latch/strike
fit by closing the latches onto the
strikes. Check that the latch closes
without having to be forced and that it
releases with ease. Adjust alignment
if necessary. Finally, install and
tighten the remaining screws.
2
3
4
6
3
4
5
6
8
SECTION C: REPLACING THE HANDLE
Models: This procedure is applicable to Pelican
™
Elite Cooler models
45QT, 45QW, 65QT, 95QT, 150QT, 250QT
Required Tools:
» Screwdriver
» Phillips head bit
1.
Lay the cooler flat on a worktable.
2.
Open the cooler lid and turn the
handle to position it inside the cooler.
3.
Remove the four Phillips head screws
that attach the bail caps to the handle.
4.
Obtain the two handle bail caps.
Notice that the caps are rounded on
one side and flat on the other. They
will be placed onto the handle with
the flat side towards the inside of the
handle and the rounded side towards
the outside of the handle, matching
the square and round bosses of the
caps with the square and round insets
in the handle.
5.
Place the handle over the molded in
handle “bar” as shown.
6.
Place one handle bail cap onto the
handle bail with the square and round
bosses in the correct orientation. Align
the screw installation holes. Start the
two screws loosely thru the handle
and into the bail cap. Repeat for the
other bail cap. Once the four screws
have been started, tighten them
completely.
SECTION D: REPLACING THE HANDLE
Models: This procedure is applicable to Pelican
™
Elite Cooler model 80QT
Required Tools:
» Screwdriver
1.
Lay the cooler flat on its lid on a worktable.
2.
Remove the Phillips head screws that attach the bail caps to the handle.
3.
Place the handle under the stop and over the handle
bar of the cooler with the handle in the extended position.
4.
Place the bail caps onto the top of the handle while lining up the square and round
bosses in the caps with the square and round recesses in the handle body.
5.
Install the four handle screws using the screwdriver. Ensure that the seams between
the handle and the bail caps are tight.
SECTION E: REPLACING THE WHEEL AXLE /
WHEELS
Models: This procedure is applicable to Pelican
™
Elite Cooler models 45QW, 55QW, 80QT
Required Tools:
» Screwdriver
» Rubber mallet or dead blow hammer
1.
Lay the cooler on its back so the wheels are facing up.
2.
Unscrew the four Phillips head screws to free the two axle
brackets. Replace the old axle with a new one.
3.
Place the axle into position. Screw the two axle brackets to
the T-nuts.
4.
To remove the old wheels:
a)
If the axle is still on the cooler, strike the inner surface
of the wheel with the rubber mallet or dead blow hammer
until the end cap is pushed free and the wheel slides off.
b)
If the axle is already removed from the cooler, clamp
the axle to a workbench or place in a vice; strike the inner
surface of the wheel with the rubber mallet or dead blow
hammer until the end cap is pushed free and the wheel
slides off.
5.
Place the wheel onto the axle with the Pelican logo facing
outwards. Place the cap nut on the end of the axle and tap
onto the axle with the rubber mallet until seated firmly.
2
Round
Square
Flat
Side
Round
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Square
Round
4
3
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6
3
5
Round
Square
Flat
Side
Round
Side
Square
Round
4
3
5
PELICAN PRODUCTS
23215 Early Avenue • Torrance, CA 90505 USA
Tel (310) 326-4700 • FAX (310) 326-3311 • www.pelican.com
PELICAN PRODUCTS ULC
10221-184th Street • Edmonton, Alberta T5S 2J4
Tel (780) 481-6076 • FAX (780) 481-9586 • www.pelican.ca
1-027-03317 5-33497 Rev A JUN/21
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