Magliner GEMINI XL User manual

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Gemini®XL Convertible Hand
Truck Owners Manual

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Table of Contents
Introduction, General Safety Instructions .............................................................................................3
Gemini Specications............................................................................................................................4
Gemini Operation .................................................................................................................................5
Converting Gemini Between 2- and 4-wheel Positions .........................................................................6
Troubleshooting.....................................................................................................................................7
Gemini Part Diagrams ....................................................................................................................... 8-9
Inspection / Maintenance Checklist.....................................................................................................10

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Thank you for using the Magliner Gemini®XL Convertible Hand Truck. Please read this manual
thoroughly to become familiar with the safe operation and maintenance of the Gemini Convertible
Hand Truck.
General Safety Instructions
• Before using your Gemini:
⋅ Carefully read this entire manual
⋅ Check tires for wear
⋅ Tighten fasteners
⋅ Check for bent or broken parts
⋅ If you see a Gemini in need of repair, replace damaged parts immediately. Never use
a Gemini that is not in proper working order. If you use a broken Gemini, you risk
damaging the delivery and more importantly you risk injuring yourself.
• Using your Gemini:
⋅ Do not exceed the weight capacity limit for the Gemini as specied in this manual
⋅ Operator should be positioned uphill from Gemini when descending on natural grades,
sloping or uneven surfaces
⋅ Avoid making sharp turns when pushing Gemini
⋅ Keep your eyes on the path
• Loading the Gemini:
⋅ Using proper alignment, lift with your legs, not your back
⋅ Head up, back straight
⋅ Never twist with your back - turn with your feet
⋅ When loading the Gemini, a balanced, stable load is best
⋅ Your load should never block your vision
⋅ Don’t overload - two trips are safer than one
• At the delivery:
⋅ Walk your path looking for obstructions, cracks, holes and uneven surfaces
⋅ Look for any vehicle or foot tra󰀩c
⋅ Note blind corners, doors and curbs
⋅ Take time to walk the delivery path. Be prepared for areas that could pose a problem
while you deliver and try to avoid them altogether, even if it means a few extra steps.
• Gemini storage:
⋅ Never leave the Gemini unattended in an aisle
⋅ Always secure the Gemini in back of truck before driving to next location
Use the Gemini only as specied in this manual

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Gemini Convertible Hand
Truck Specications
Gemini Components
A. Upper handle (sometimes referred to as the “B-handle”) for ergonomic hand/shoulder
placement during pushing
B. Lower horizontal loop handle for maneuvering in the 2-wheel position
C. 6” x 2” swivel casters with parking brake (to be used on level surfaces only)
D. 10” 4-ply tube type pneumatic wheels o󰀨er excellent shock absorption and starting roll-force
E. Wide extruded aluminum nose carries a wide variety of products
F. Latch and lock mechanism securely locks Gemini in the 2-wheel position
G. Solid deck prevents smaller items from falling through the frame
Gemini Capacity and Gemini Weight
The Gemini can be used in the 2-wheel position and in 4-wheel position. The Gemini capacity in
the 2-wheel position is 500 lbs.; Gemini capacity in the 4-wheel position is 1,250 lbs.
The Gemini XL weighs 54 lbs.
B
E
A
C
F
D
G

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Delivery Gemini Operation
When do I use in 2-wheel position?
Although the Gemini can be used for many di󰀨erent load variations, typical 2-wheel delivery
scenarios may include the following (500 lbs. maximum):
• When mixed items are delivered to the same location
• For deliveries where it is necessary to transport a mix of up to:
• Limited space deliveries
• Frequent stairwells and curbs
• Busy freight elevator usage
• High density of pedestrians
• For deliveries weighing no more than 500 lbs.
When do I use in 4-wheel position?
Although the Gemini can be used for many di󰀨erent load variations, typical 4-wheel delivery
scenarios may include the following (1,250 lbs. maximum, DO NOT use on stairwells in the
4-wheel position):
• When mixed items are delivered to the same location
• For deliveries weighing up to 1,250 lbs.
• Delivery area is free of steps, curbs, etc.

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Note: Be sure to allow adequate room on a at, clear surface for converting the truck between 2- and
4-wheel positions. Caution: While converting the Gemini between the 2- and 4-wheel positions, take
care to keep hands out of the way of moving parts.
From 2-wheel to 4-wheel:
1. Hold the Gemini securely with one hand on upper handle and the other hand on the top frame
cross member; press release latch (see Figure 1)
2. Keeping the upper handle as perpendicular to the ground as possible, slide the frame down the
upper handle until the handle plate rests on the spreader rod (see Figures 2 and 3).
3. You are now ready to use the Gemini in the 4-wheel position
Converting Gemini Between 2- and 4-wheel Positions
Figure 1 Figure 2 Figure 3
Figure 4 Figure 5 Figure 6
Release Latch
From 4-wheel to 2-wheel:
1. Place one hand securely on the upper handle and the other hand on the top frame cross member
2. Keeping the upper handle as perpendicular to the ground as possible, begin to slide the frame up the
upper handle (see Figure 5). Continue lifting the frame to the top of the upper handle as you orient the
frame so that it becomes perpendicular to the ground (see Figures 5 and 6).
3. With the Gemini wheels and nose resting squarely on the ground, swing the bottom of the upper handle
toward the Gemini frame so that the spreader rod locks rmly in place with the latch/lock assembly (see
Figure 6)
4. You are now ready to use the Gemini in the 2-wheel position

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Troubleshooting
The Gemini XL is di󰀩cult to transition between 2- and 4-wheel positions.
 Is the upper handle bent to where it should be replaced?
 Are there burrs or other damage on the upper handle? File or sand smooth, or replace the
handle.
 Are the pivot sockets damaged or bent and should be replaced?
 Replace worn, damaged or missing components.
The Gemini XL frame will not latch when in the 2-wheel position.
 Are the latch components in place and in good condition?
 Is the latch rod in place and in good condition?
 Are latch component mounting screws loose? Tighten mounting screws.
 Replace worn, damaged or missing components.
The Gemini XL does not roll smoothly.
 Are the main wheels loose?
 Are the caster brakes applied?
 Are the bearings in the main wheels free and in good working order?
 Are the brackets on the casters bent or broken?
 Do the casters swivel easily?
 Are there at spots on the main wheels or caster wheels?
 Replace worn, damaged or missing components.

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GEMINI®CONVERTIBLE HAND TRUCK PART DIAGRAMS
XLSP/XLAP
81077 x 2
22118
190104 x 2
121060
3027220
80045 x 2
80713 x 2
80713 x 2
80605 x 2
80707 x 2
80705 x 4
302782
80144 x 4
80676 x 4
301008
130025 x 2
302724
210100
210101

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• (1) #3 PHILLIPS SCREWDRIVER
• (1) 7/16” COMBINATION WRENCH
• (1) 1/2” COMBINATION WRENCH
• (2) 5/8” COMBINATION WRENCH OR
SOCKET
• (1) NEEDLE NOSE PLIERS
• (1) HAMMER
TOOLS REQUIRED
Part Description Part Number
Handle assembly 3027220
Caster - 6” x 2” with brake 130025
Extruded aluminum nose - 18” wide 302782
Wheel - 10” 4-ply tube type pneumatic 121060
Latch and lock assembly for Gemini XL 302724
Axle - 20” long 22118
Axle roll pin - 1/8” x 1-1/8” long 190104
Hex head cap screw - 7/16”-14 x 3-3/4” long 80045
Flat washer - 7/16” 80713
Lock nut - 7/16”-14 80605
Carriage bolt - 5/16”-18 x 1” long 80144
Lock nut - 5/16”-18 80676
Washer - 5/8” x 3/32” (thick) 80705
Washer - 5/8” x 1/32” (thin) 80707
Cotter pin for axle - 1/8” x 1” long 81077
No. 19 standard U-loop with vinyl sleeve 301008
Handle mounting bolt - 1/4”-20 x 2-1/2” long 80108
Lock nut - 1/4”-20 80675
Wheel bracket - RH 210100
Wheel bracket - LH 210101

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Form # B9596
© Copyright 2021, Magline, Inc.
Magline, Inc.
1205 W. Cedar Street • Standish, MI 48658 USA
1-800-MAGLINE (624-5463) • [phone] (outside U.S. & Canada)
www.magliner.com
Inspection Date: ____________ Customer Location: ____________________ Inspector’s Name: ____________
NotesTiming
Daily Daily Daily Daily Daily
Findings
Pass or Fail
Normal Condition
• Frame is not twisted or bent • Latch and lock assembly is
not bent or damaged
• Upper handle is not bent or
damaged
• Straight sections • Smooth curves • Flat surfaces
Gemini should easily convert from 2- to 4-wheel position (some lubrication may be required over time)
• There should be no chunks
missing from the wheel material
• The hub is not cracked or
damaged
• No missing cotter pins • No loose fasteners • No missing fasteners
Method of
Inspection
Visual inspection Visual inspection Follow conversion steps to fold and unfold Gemini Visual inspection Visual inspection
Description
Gemini is straight and properly aligned Gemini shows no damage or excessive wear Gemini folds and unfolds properly Gemini wheels, casters and caster brakes are in good condition Fasteners
Area
General Inspection General Inspection General Inspection General Inspection General Inspection