gemini - Magliner
ASSEMBLY INSTRUCTIONS
GEMINI
®
Bulk Container Edition
Table of Contents: Parts List ........................................... 2 Assembly Instructions ..................2-4
www.magliner.com
TOOLS REQUIRED
• (1) 7/16” WRENCH OR SOCKET • (2) 1/2” WRENCHES OR SOCKETS • (1) 9/16” WRENCH • (1) 7/8” WRENCH OR SOCKET • (1) HAMMER • (1) PLIERS • (1) #2 PHILLIPS SCREW DRIVER
PARTS LIST Item
Description
Qty.
Part No.
1
Upper handle assembly
1
301767 (or 301776 handle with hook)
2
RH wheel bracket
1
210100
3
LH wheel bracket
1
210101
4
Nose plate
1
Varies
5
18" axle
1
22101
6
Wheel
2
Varies
7
Side channel reinforcement
2
302001
8
Lower handle
1
301000 or 301008
10
Caster assembly
2
Varies
Spreader Rod and Bolt Kit consists of items below: 9
Spreader rod and bracket assembly
1
301058
17
Load bolt
2
301049
18
Spacer for load bolt
2
301061
19
Hex lock nut - 3/8"-16
2
80603
Hardware Pack consists of items below: 12
Hex head screw - 5/16"-18 x 2-1/4"
4
80017
11
Pin coil spring 1/8" x 1-1/8"
2
190104
13
Hex lock nut - 5/16"-18
4
80676
14
5/8" washer thin
4
80707
15
5/8" washer thick
4
80705
16
Cotter pin
2
81077
20
Pan head machine screw - 1/4"-20 x 1-3/2" long
4
80105
21
Hex lock nut - 1/4"-20
4
80675
The following assembly sequence is recommended:
STEP 1:
1. ASSEMBLING OF THE FRAME, FRAME REINFORCEMENTS, NOSE, WHEEL BRACKETS, AND AXLE.
Use a workbench or table of convenient height and place all components in view and within reach. a. Install the two (2) side channel reinforcements into the nose end of the frame making certain holes are aligned (Refer to Figure 2). b. Slide the legs of the frame down and over the embossments on the heel of the nose casting (Refer to Figure 2). c. Insert the four 5/16”-18 hex head bolts through the nose, frame reinforcements, and the frame legs. Do Not Secure The Bolts At This Time! (Refer to Figure 2) d. Install right hand wheel bracket over the protruding bolts. Secure with two 5/16”-18 hex head locknuts. Do Not Tighten The (2) Nuts At This Time! (Refer to Figure 2); (Reference Figure 1 for correct axle hole position). e. Install one roll pin in the axle and center the pin on the axle, tapping lightly with a hammer (Refer to Figure 4). Repeat for the second roll pin. f. Insert the axle through the UPPER axle hole. NOTE: Rotate axle until roll pin "locks" into position in the wheel bracket (Refer to Figure 1). •Note• If Stair Climbers are used, refer to the assembly instructions that were provided with them. If Stair Climbers are not used, continue to Step g. g. Position and attach the left hand wheel bracket sliding it over the axle to the outside of the frame leg, using two 5/16”-18 hex head locknuts to secure it. Do Not Tighten The (2) Nuts At This Time! (Refer to Figure 2). h. Check all components for proper location at this time. Make any adjustments required. i. Securely tighten nose and wheel bracket bolts.
STEP 2:
ASSEMBLING THE WHEELS. (Refer to Figure 4)
a. Slide one thick and one thin wheel washer onto the axle up to the wheel bracket. b. Slide a wheel on the axle up to the washer (the long hub portion is toward or next to the wheel bracket and washer). c. Slide the thin wheel washer onto the axle up to the wheel. d. Insert the cotter pin through the hole at the end of the axle and spread the ends of the cotter pin apart using the pliers. • Repeat above assembly sequence for the second wheel.
2
Figure 1
Upper Axle Hole
Lock Mechanism (Groove)
Figure 2
3
2 13 Left Hand Wheel Bracket
13
7 4
Figure 3
16 16
11
5 6 14
6 15
14
14 15
14
3
STEP 3:
ASSEMBLING THE UPPER HANDLE AND CASTERS. (Refer to Figures 4 & 5)
a. (Refer to Figure 4 ) While the hand truck is in the upright position, orient the upper handle as shown in Figure 4 with the bent portion on top. Slide the upper handle into the pivot sockets until at least 6" of the handle end extends past the pivot sockets. b. Slide the spreader rod and bracket assembly onto the upper handle with the spreader rod on top until the holes in the bracket are aligned with the holes in the upper handle. c. Slide the stem of one of the caster assemblies into one of the open ends of the upper handle so that the hole in the caster stem is aligned with the holes of the upper handle and spreader bracket. Using the 7/8” and 9/16” wrenches, securely fasten with one lock nut, one load bolt and one spacer in the order shown in Figure 5. Repeat on the other side for the second caster, making sure the head of the bolt is on the inside of the upper handle (toward frame) and the lock nut is on the outside of the upper handle (away from the frame).
Figure 5 Casters Figure 4 Upper Handle
17
1
18 19
9
Pivot socket
8 21 20 Figure 6 Lower Handle
STEP 4:
ASSEMBLING THE HANDLE. (Refer to Figure 6)
a. (Refer to Figure 5 ) Position the ends of the handle in the provided handle brackets and line up the holes. Secure with four 1/4"-20 pan head screws and four locknuts. b. Tighten the handle screws on the preassembled mounting brackets and the handle bracket screws securely. NOTE: Tighten 1/4" screws to 50-60 in.-lbs., 5/16" screws to 120-140 in.-lbs. and 3/8" screws to 120-140 in.-lbs.
www.magliner.com
Magline, Inc., 1205 West Cedar Street, Standish, MI 48658 • (800) 624-5463 • (989) 512-1000 B9315
© Copyright 2014 Magline, Inc.
4
GEMINI
®
Bulk Container Edition
Table of Contents: Parts List ........................................... 2 Assembly Instructions ..................2-4
www.magliner.com
TOOLS REQUIRED
• (1) 7/16” WRENCH OR SOCKET • (2) 1/2” WRENCHES OR SOCKETS • (1) 9/16” WRENCH • (1) 7/8” WRENCH OR SOCKET • (1) HAMMER • (1) PLIERS • (1) #2 PHILLIPS SCREW DRIVER
PARTS LIST Item
Description
Qty.
Part No.
1
Upper handle assembly
1
301767 (or 301776 handle with hook)
2
RH wheel bracket
1
210100
3
LH wheel bracket
1
210101
4
Nose plate
1
Varies
5
18" axle
1
22101
6
Wheel
2
Varies
7
Side channel reinforcement
2
302001
8
Lower handle
1
301000 or 301008
10
Caster assembly
2
Varies
Spreader Rod and Bolt Kit consists of items below: 9
Spreader rod and bracket assembly
1
301058
17
Load bolt
2
301049
18
Spacer for load bolt
2
301061
19
Hex lock nut - 3/8"-16
2
80603
Hardware Pack consists of items below: 12
Hex head screw - 5/16"-18 x 2-1/4"
4
80017
11
Pin coil spring 1/8" x 1-1/8"
2
190104
13
Hex lock nut - 5/16"-18
4
80676
14
5/8" washer thin
4
80707
15
5/8" washer thick
4
80705
16
Cotter pin
2
81077
20
Pan head machine screw - 1/4"-20 x 1-3/2" long
4
80105
21
Hex lock nut - 1/4"-20
4
80675
The following assembly sequence is recommended:
STEP 1:
1. ASSEMBLING OF THE FRAME, FRAME REINFORCEMENTS, NOSE, WHEEL BRACKETS, AND AXLE.
Use a workbench or table of convenient height and place all components in view and within reach. a. Install the two (2) side channel reinforcements into the nose end of the frame making certain holes are aligned (Refer to Figure 2). b. Slide the legs of the frame down and over the embossments on the heel of the nose casting (Refer to Figure 2). c. Insert the four 5/16”-18 hex head bolts through the nose, frame reinforcements, and the frame legs. Do Not Secure The Bolts At This Time! (Refer to Figure 2) d. Install right hand wheel bracket over the protruding bolts. Secure with two 5/16”-18 hex head locknuts. Do Not Tighten The (2) Nuts At This Time! (Refer to Figure 2); (Reference Figure 1 for correct axle hole position). e. Install one roll pin in the axle and center the pin on the axle, tapping lightly with a hammer (Refer to Figure 4). Repeat for the second roll pin. f. Insert the axle through the UPPER axle hole. NOTE: Rotate axle until roll pin "locks" into position in the wheel bracket (Refer to Figure 1). •Note• If Stair Climbers are used, refer to the assembly instructions that were provided with them. If Stair Climbers are not used, continue to Step g. g. Position and attach the left hand wheel bracket sliding it over the axle to the outside of the frame leg, using two 5/16”-18 hex head locknuts to secure it. Do Not Tighten The (2) Nuts At This Time! (Refer to Figure 2). h. Check all components for proper location at this time. Make any adjustments required. i. Securely tighten nose and wheel bracket bolts.
STEP 2:
ASSEMBLING THE WHEELS. (Refer to Figure 4)
a. Slide one thick and one thin wheel washer onto the axle up to the wheel bracket. b. Slide a wheel on the axle up to the washer (the long hub portion is toward or next to the wheel bracket and washer). c. Slide the thin wheel washer onto the axle up to the wheel. d. Insert the cotter pin through the hole at the end of the axle and spread the ends of the cotter pin apart using the pliers. • Repeat above assembly sequence for the second wheel.
2
Figure 1
Upper Axle Hole
Lock Mechanism (Groove)
Figure 2
3
2 13 Left Hand Wheel Bracket
13
7 4
Figure 3
16 16
11
5 6 14
6 15
14
14 15
14
3
STEP 3:
ASSEMBLING THE UPPER HANDLE AND CASTERS. (Refer to Figures 4 & 5)
a. (Refer to Figure 4 ) While the hand truck is in the upright position, orient the upper handle as shown in Figure 4 with the bent portion on top. Slide the upper handle into the pivot sockets until at least 6" of the handle end extends past the pivot sockets. b. Slide the spreader rod and bracket assembly onto the upper handle with the spreader rod on top until the holes in the bracket are aligned with the holes in the upper handle. c. Slide the stem of one of the caster assemblies into one of the open ends of the upper handle so that the hole in the caster stem is aligned with the holes of the upper handle and spreader bracket. Using the 7/8” and 9/16” wrenches, securely fasten with one lock nut, one load bolt and one spacer in the order shown in Figure 5. Repeat on the other side for the second caster, making sure the head of the bolt is on the inside of the upper handle (toward frame) and the lock nut is on the outside of the upper handle (away from the frame).
Figure 5 Casters Figure 4 Upper Handle
17
1
18 19
9
Pivot socket
8 21 20 Figure 6 Lower Handle
STEP 4:
ASSEMBLING THE HANDLE. (Refer to Figure 6)
a. (Refer to Figure 5 ) Position the ends of the handle in the provided handle brackets and line up the holes. Secure with four 1/4"-20 pan head screws and four locknuts. b. Tighten the handle screws on the preassembled mounting brackets and the handle bracket screws securely. NOTE: Tighten 1/4" screws to 50-60 in.-lbs., 5/16" screws to 120-140 in.-lbs. and 3/8" screws to 120-140 in.-lbs.
www.magliner.com
Magline, Inc., 1205 West Cedar Street, Standish, MI 48658 • (800) 624-5463 • (989) 512-1000 B9315
© Copyright 2014 Magline, Inc.
4
