Magliner GEMINI XL User manual

Assembly Instructions
www.magliner.com
Table of Contents:
Parts List ...................................2
Assembly Instructions ..............3
Warranty Information .............4

A
B
L
G
F
GF
F
F
K
H
H
L
C
E
E
EE
D
C
A
J
A
A
B
B
B
Hardware Pack consists of items below: 1 85981
ASquare Neck Carriage Bolt, 5/16-18 X 1" Lg. 4 80144
B Nylon Top Lock Nut, 5/16-18 4 80676
C Hex Head Bolt, 7/16-14 X 3-3/4" Lg. 2 80045
D Lock Nut, 7/16-14 2 80605
E Handle Washer, 3/4" OD X .463" ID 4 80713
F Thick Washer, 1-5/16" OD X 5/8" ID 4 80705
G Thin Washer, 1-5/16" OD X 5/8" ID 2 80711
H 90 Degree Hairpin Cotter 2 81139
J Handle Assembly 1 3027231
K Aluminum Nose 1 302782
L Wheel, 1060 2 121040
O Wheel, 1030 2 10830
I Straight Hairpin Cotter (for 1030 wheel option) 2 81142
M Folding Contaiment Arm 1 302725
R Nylon Top Lock Nut, 5/16-18 2
N Pan Head Bolt, 5/16-18x1” 2
ITEM DESCRIPTION QTY. PART NO.
PARTS LIST
TOOLS REQUIRED
•(2) 1/2” COMBINATION
WRENCH
•(1) 5/8” COMBINATION
WRENCH
•(1) 7/16” COMBINATION
WRENCH
•(1) #3 PHILLIPS SCREW
DRIVER (NEEDED
ONLY FOR OPTIONAL
CONTAINMENT ARM
INSTALLATION)
•(1) 11/16” SOCKET AND
RATCHET
FIGURE 1
for folding containment
arm option
O
I
I
O
1030 Wheel Option
FIGURE 2
85975
2
Optional Items

STEP 1: ASSEMBLE THE NOSE AND WHEELS TO THE FRAME
Nose Assembly
Note: for easier assembly it may be necessary to lay the truck horizontally to attach the nose.
1. Position the nose (K) on the mounting brackets so the square holes align with each other.
2. Insert one (1) square neck carriage bolt (A), with head of bolt toward the front of the nose plate, in
each of the four (4) holes. Secure each of the four (4) carriage bolts (K) with four (4) nylon top lock
nuts (B), tighten securely. (torque value of 120-140 in-lbs.)
Wheel Assembly
1. Slide one (1) thick washer (F) on the axle, slide one (1) thin washer (G) on the axle.
2. Slide wheel (L) onto the axle with the long hub portion facing in.
3. Slide one (1) thick washer (G) on the axle.
4. If using 1030 wheel, insert one (1) straight hairpin cotter (I) though hole on the end of the axle,
as shown in Figure 2.
5. For all other wheels, insert one (1) 90 degree hairpin cotter (H).
6. Repeat steps 1 through 5 for other wheel.
STEP 2: ASSEMBLE THE HANDLE
1. Position the handle assembly (J) so holes in the pivot sockets align with holes in the pivot plate,
with one (1) handle washer (E) between each of them. Note: washers must be placed in correct
location to ensure proper handle fit.
2. Insertone (1) hex head bolt (C) through the pivot socket and pivot plate.
3. Slide one (1) handle washer (E) on the hex head bolts and thread on one (1) locknut (D) by hand.
4. Repeat steps 1 through 3 for other pivot socket.
5. Using socket, tighten bolt to remove all free play,then loosen 1/2 turn. Adjust bolts as necessary to
allow handle to slide freely.
STEP 3: ASSEMBLE THE LOAD CONTAINMENT ARM (OPTIONAL ITEM)
1. Insert both bolts (N) in the Load
Containment Arm brackets and the
extruded nose hole, as shown in Figure3,
and tighten the nuts (R) securely.(torque
value of 120-140 in-lbs.)
2. If required, tighten the other nuts on the
Load Containment Arm brackets until the
load containment arm can be repositioned
and remain in its repositioned
location. Do not over tighten.
M
R
N
N
Folding Containment ArmOption
FIGURE 3
3

Date of Purchase Record
Fax this formto Magline, Inc. 1-800-968-7504.
Please Print All Information Clearly
Purchase Date: ________________________________________________
Company Name: _______________________________________________
Contact Name: ________________________________________________
Title: _________________________________________________________
E-mail: _______________________________________________________
Address: ______________________________________________________
City: ______________________ State: ____ Postal Code:___________
Country: ______________________________________________________
Phone: _______________________________________________________
Fax:___________________________________________________________
Purchased From: ______________________________________________
Product Purchased: ____________________________________________
Model Number: _______________________________________________
No. of Routes: ________________________________________________
Business Type:
____ Beer ____ Soft Drink ____ Healthcare
____ Food Service ____ Parcel
____ Bakery ____ Snacks
____ Vending ____ Bottled Water
____ Other: _______________________________
503 South Mercer Street
Pinconning, Ml 48650 USA
1-800-MAGLINE (624-5463)
[phone] (outside U.S. & Canada)
[e-mail]
www.magliner.com
B7981 ©Copyright 2004, Magline, Inc.
WARRANTY INFORMATION
Magline One-Year Limited Warranty
Magliner products have a one (1) year warranty from the date of purchase against defects in workmanship or
material.
Any part or component, except items covered by warranties of other manufacturers, returned to the factory or
service center freight prepaid by the owner, found upon examination by Magline, Inc. to be defective or the result
of improper workmanship by the factory will be repaired or replaced without charge and returned to the owner
freight prepaid by Magline, Inc.
Alterations of Magliner products void any warranty or liability on the part of Magline, Inc. Magline does not
guarantee product capacity if alterations are made.
In 1947, Magline, Inc. introduced the
first light weight Magliner hand trucks
to American businesses.
Today, our route delivery solutions have
expanded -- globally. You’ll find
Magline’sfamily of hand trucks, ramps,
and dock products in route delivery
operations all over the world.
People have trusted the Magline name
for more than half a century. For
performance, durability, and safety,
you’ll discover what millions of route
deliveryprofessionals around the world
already know -- no other equipment
measures up to a Magliner.
Thank you for your purchase and
welcome to the Magliner family!
4