Magliner MAG220 User manual

1
Assembly Instructions
www.magliner.com
Magline, Inc., 1205 West Cedar Street, Standish, MI 48658 • [phone] • [phone]
Table of Contents:
Nose, Wheel Brackets, Axle
Assembly ....................................2-3
Handle, Rear Brace, Support Loop
Brace Assembly ............................. 4
Wheel Assembly ........................... 5
Trayless Four Bottle
Water Hand Truck
*NOTE: Load and unload in the horizontal position only - Do
not stand the truck in the upright position when loaded with
water bottles.

2
I
H
E
E
F
A
BD
G
I
J
Figure 1
x
C
Use a workbench or table of convenient height and place all components in view and within reach.
1. Assemble hand truck frame, nose assembly and RH wheel bracket.
a. Slide the frame (B) down and over the RH and LH nose mounting brackets on the nose plate assembly
(A), temporarily inserting one 5/16"-18 x 1-1/4" long hex head screw (I) through the upper hole of the LH nose
mounting bracket and the upper frame mounting hole.
b. Position and attach the RH wheel bracket (G) to the outside of the frame leg, aligning the mounting holes with the
frame and RH nose mounting bracket holes. Insert two 5/16"-18 x 1-1/4" long hex head screws (I) through the
wheel bracket mounting holes and thread on one 5/16"-18 hex lock nut (J) (see Figure 1). NOTE: Do not tighten
securely at this time.
2. Install roll pin and shaft collars.
a. Install the first roll pin (C) in the axle (D), tapping lightly with hammer to center the pin on the axle (see Figure 2).
b. Slide one shaft collar (E) onto the axle (D). Next slide on the rear support brace (F) followed by the second shaft
collar (E) (see Figure 2). Do not tighten the shaft collars against the axle at this time.
3. Assemble LH wheel bracket to hand truck frame.
a. Insert the axle (D) (the end with the roll pin in place) through the lower axle hole in the RH wheel bracket (G)
(labeled x on Figure 1). NOTE: Rotate axle until roll pin "locks" into position in the wheel bracket.
b. Position and attach the LH wheel bracket (H), sliding it over the axle to the outside of the frame leg. Insert one
5/16"-18 x 1-1/4" long hex head screw (I) through the bottom mounting hole of the wheel bracket, frame and nose
mounting bracket; then thread on one 5/16"-18 hex lock nut (J). Remove the upper 5/16"-18 x 1-1/4" long screw
and re-install through the upper mounting hole of the wheel bracket; thread on one 5/16"-18 hex lock nut (see
Figure 1). NOTE: Do not tighten securely at this time.
4. Install the other roll pin (C), tapping lightly with hammer to center.
ASSEMBLE THE NOSE, WHEEL BRACKETS AND AXLE TO THE FRAME - 8" WHEELS ONLY
Item Description Qty. Part No.
A Nose plate assembly 1 301482
B Frame 1 3014680
C Roll pin for axle 2 190104
D Axle - 18" long (815 wheels use 22100 axle) 1 22101
E Shaft collar - 5/8" ID 2 83051
F Rear support brace 1 301475
G RH wheel bracket 1 210100
H LH wheel bracket 1 210101
I Hex head cap screw - 5/16"-18 x 1-1/4" long 4 80012
J Hex lock nut - 5/16"-18 4 80676
TOOLS REQUIRED
• 1/2” DEEP WELL SOCKET
AND RATCHET
• 7/16” DEEP WELL SOCKET
AND RATCHET
• 5/32 ALLEN WRENCH
• #2 PHILLIPS SCREWDRIVER
• HAMMER
• PLIERS
D
E
E
C
F
Figure 2

3
Item Description Qty. Part No.
A Nose plate assembly 1 301482
B Frame 1 3014680
C Roll pin for axle 4 190104
D Axle - 18" long 1 22101
E Shaft collar - 5/8" ID 2 83051
F Rear support brace 1 301475
G RH wheel bracket 1 210100
H LH wheel bracket 1 210101
I Hex head cap screw - 5/16"-18 x 1-1/4" long 4 80012
J Hex lock nut - 5/16"-18 4 80676
KRear support mount for 10" wheel option - 12.6" long 1 301483
Use a workbench or table of convenient height and place all components in view and within reach.
1. Assemble hand truck frame, nose assembly and RH wheel bracket.
a. Slide the frame (B) down and over the RH and LH nose mounting brackets on the nose plate assembly
(A), temporarily inserting one 5/16"-18 x 1-1/4" long hex head screw (I) through the upper hole of the LH nose
mounting bracket and the upper frame mounting hole.
b. Position and attach the RH wheel bracket (G) to the outside of the frame leg, aligning the mounting holes with the
frame and RH nose mounting bracket holes. Insert two 5/16"-18 x 1-1/4" long hex head screws (I) through the
wheel bracket mounting holes and thread on one 5/16"-18 hex lock nut (J) (see Figure 3). NOTE: Do not tighten
securely at this time.
2. Install roll pin and shaft collars.
a. Install the first roll pin (C) in the rear support mount (K), tapping lightly with hammer to center the pin on the
support mount (see Figure 4).
b. Slide one shaft collar (E) onto the support mount (K). Next slide on the rear support brace (F) followed by the
second shaft collar (E) (see Figure 4). Do not tighten the shaft collars against the support mount at this time.
c. Install one roll pin (C) in the axle (D), tapping lightly with hammer to center the pin on the axle.
3. Assemble LH wheel bracket to hand truck frame.
a. Insert the support mount (K) (the end with the roll pin in place) through the lower axle hole in the RH wheel bracket
(G) (labeled x on Figure 3). NOTE: Rotate support mount until roll pin "locks" into position in the wheel bracket.
b. Insert the axle (D) (the end with the roll pin in place) through the upper axle hole in the RH wheel bracket (G)
(labeled y on Figure 3). NOTE: Rotate axle until roll pin "locks" into position in the wheel bracket.
c. Position and attach the LH wheel bracket (H), sliding it over the axle and support mount to the outside of the frame
leg. Insert one 5/16"-18 x 1-1/4" long hex head screw (I) through the bottom mounting hole of the wheel bracket,
frame and nose mounting bracket; then thread on one 5/16"-18 hex lock nut (J). Remove the upper 5/16"-18 x
1-1/4" long screw and re-install through the upper mounting hole of the wheel bracket; thread on one 5/16"-18 hex
lock nut (see Figure 3). NOTE: Do not tighten securely at this time.
4. Install the other roll pins (C) in the support mount and axle, tapping lightly with hammer to center.
ASSEMBLE THE NOSE, WHEEL BRACKETS AND AXLE TO THE FRAME - 10" WHEELS ONLY
TOOLS REQUIRED
• 1/2” DEEP WELL SOCKET
AND RATCHET
• 7/16” DEEP WELL SOCKET
AND RATCHET
• 5/32 ALLEN WRENCH
• #2 PHILLIPS SCREWDRIVER
• HAMMER
• PLIERS
K
E
E
C
F
Figure 4
C
F
A
EB
D
I
H
G
I
J
x
C
Figure 3
y

4
ASSEMBLING THE HANDLE, REAR BRACE AND SUPPORT LOOP BRACE (ALL MODELS)
1. Insert handle with black grip (L) inside the rear support brace (F) with the hand grip facing away from the nose
(see Figure 5). Insert two 1/4"-20 x 1-1/4" long screws (N) through the brace and handle and secure with 1/4"-
20 hex lock nuts (O) (tighten screws to 50-60 in.-lbs. torque). NOTE: The 1/4"-20 lock nuts will sit down in the
groove on the handle stub when assembled, eliminating the need for the 7/16" wrench when tightening the
screw.
2. Rotate the handle with rear support brace up to the top of the frame, aligning the two bracket holes with the
holes through the top of the frame (see Figure 5). Insert two 1/4"-20 x 3/4" long screws (M) through the bracket
and frame and secure with 1/4"-20 hex lock nuts (O) (tighten screws to 50-60 in.-lbs. torque).
3. Slide the rear support brace (F) along the axle (8" models) or rear support mount (10" models) so it is centered
between the two wheel brackets. Slide both shaft collars (E) up against the rear support brace (F) and securely
tighten the shaft collar set screws against the axle or mount using the 5/32" Allen wrench.
4. Check axle, wheel brackets, rear support brace and nose for proper location at this time. Make any required
adjustments. Securely tighten the nose and wheel bracket screws at this time (tighten the 1/4"-20 screws to 50-
60 in.-lbs. torque and the 5/16"-18 screws to 120-140 in.-lbs. torque).
5. Install the support loop brace (P), aligning the brace mounting holes with the frame holes (see Figure 5). Insert
one 1/4"-20 x 3/4" long screw (M) through a brace mounting hole, using light blows with a hammer to pierce
through the red stripe. Thread on one 1/4"-20 hex lock nut (O). Repeat this step to install the remaining three
mounting screws. Securely tighten the four loop brace screws at this time (tighten the 1/4"-20 screws to 50-60
in.-lbs. of torque).
Item Description Qty. Part No.
LHandle with black grip 1 301469
MPan head machine screw - 1/4"-20 x 3/4" long 6 80256
N Pan head machine screw - 1/4"-20 x 1-1/4" long 2 80104
O Hex lock nut - 1/4"-20 8 80675
P Support loop brace 1 301473
F Rear support brace 1 301475
Figure 5
O
M
L
N
P
M
O
F

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B9247 © Copyright 2012 Magline, Inc. REV 5/12
ASSEMBLING THE WHEELS (ALL MODELS)
1. Slide two thick 5/8” washers (Q) on the axle.
2. Slide one wheel (R) onto the axle, making sure the long hub portion is toward the wheel bracket.
3. Slide one thin 5/8” washer (S) on the axle (see Figure 6).
4. Insert one cotter pin (T) through the hole on the end of the axle and spread the ends of the cotter pin apart using
a regular screwdriver and a hammer.
5. Repeat steps 1-4 for the second wheel.
Item Description Qty. Part No.
QFlat washer - 5/8" (thick) 4 80705
RWheel 2Varies
SWasher - 5/8" x 1/32" (thin) 2 80707
T Cotter pin for axle - 1/8" x 1" long 2 81077
Figure 6
YOU ARE NOW READY TO PUT YOUR MAGLINER HAND TRUCK TO WORK.*
Q
T
S
R
*NOTE: Load and unload in the horizontal position only - Do not stand the truck in the upright position
when loaded with water bottles.