FUNKY MONKEY BARS THE ORANGUTAN User manual

THE ORANGUTAN
ASSEMBLY INSTRUCTIONS

CONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
Load Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
Assembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
Ladder Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
Leg Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
Twirly Whirly Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 16
Main Monkey Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 17
Swing Bar and Leg Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 19
Load Twirly Whirly Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 23
Sticker Placement Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 26
Page 1
SAFETY NOTICE
1. Any person handling or using the Funky Monkey Bars® products must follow the instructions as described
in this document. The person in charge of assembling and using the equipment must ensure that the
recommendations for use given in this document are seen by all users.
2. Only use the Funky Monkey Bars® after they have been fully assembled and after checking that the
fittings are tightened properly (refer to page 5 - Correct Tightening Method).
3. DO NOT install your Funky Monkey Bars® over concrete, asphalt, packed earth, wood decking or any
other hard surface. A fall onto a hard surface can result in serious injury or death.
4. Inspect all grub screws, bolts and nuts at the beginning of each play session to ensure your Funky Monkey
Bars® are tight and secure.
5. Ensure all tubes are fully inserted into fittings until you hear the magic “CLUNK” sound.
6. Ensure your Funky Monkey Bars® are properly secure at ALL times. Pegs are in place and inserted fully into
the ground.
7. DO NOT exceed the maximum load/weight limit as recommended by Funky Monkey Bars®.
8. Children should be supervised by an adult at all times.
9. Installing a gym/crash mat under the fall zone area of your Funky Monkey Bars® would be recommended
for children learning this new skill. This will reduce the chance of injury and build the child’s confidence
while they build strength and master the skill.
10. Ensure you have thoroughly read your assembly and installation instructions and viewed our on-line
installation videos at https://www.funkymonkeybars.com/blogs/installation-maintenance-videos
11. DO NOT climb, sit or stand on top of the monkey bar (horizontal ladder) section.
12. DO NOT jump from the top of any section of the monkey bar.
13. DO NOT use your Funky Monkey Bars® when wet as the steel will be slippery.
14. DO NOT attach items to your frame that are not designed specifically to be used with Funky Monkey
Bars®, especially lower quality products that have not been approved by Funky Monkey Bars®.
15. Ensure the height of your Funky Monkey Bars® (horizontal ladder) are set at a level that is age appropriate.
16. DO NOT install your Funky Monkey Bars® over or near objects that could interfere with users in an unsafe
way. Maintain a clear area around your Funky Monkey Bars®.
17. DO NOT use your Funky Monkey Bars® while under the influence of drugs and alcohol.
18. Wear clothing free of drawstrings, hooks, loops or anything that could get caught while using your Funky
Monkey Bars® and result in entanglement and/or strangulation.
WARNING
PLEASE CAREFULLY READ ALL INFORMATION CONTAINED IN THIS ASSEMBLY MANUAL BEFORE
YOU INSTALL AND USE YOUR FUNKY MONKEY BARS®.
WARNINGS

Page 2
LOCATION
1. A safe fall zone around your Funky Monkey Bars® is essential. A minimum distance of 1.5m to 2m (5 ft to
6.5ft) is recommended around the elevated hanging points of your Funky Monkey Bars®.
2. Place your Funky Monkey Bars® on level ground, away from any structure or obstruction such as a fence,
garage, house, overhanging branches, laundry lines or electrical wires and remove any obstructions
beneath your Funky Monkey Bars®.
3. Ensure your Funky Monkey Bars® are positioned away from retaining walls, pool fences, structures and
other play equipment. Maintain a clear space around the whole perimeter of your Funky Monkey Bars®.
4. Place your Funky Monkey Bars® on the most level surface available.
MAINTENANCE
1. At the beginning of each heavy play session we recommend the following maintenance processes be
performed on your Funky Monkey Bars®:
• Tighten all bolts, grub screws and applicable hardware (as per page 5)
• Lubricate all metallic moving parts as per instructions (flying fox, swing hooks etc)
• Check all protective coverings on bolts, pipes, edges and corners. Replace if they are loose,
cracked or missing.
• Check all moving parts including swing seats, shackles, snap hooks, chains and trolleys for wear,
rust, or other deterioration. Replace as needed.
2. Twice a month during play season we would recommend the following maintenance processes be
performed on your Funky Monkey Bars®:
• Tighten all connections and hardware
• Check all protective coverings on bolts, pipes, edges and corners. Replace if they are loose,
cracked or missing.
3. Once a month during play season we would recommend the following maintenance processes be
performed on your Funky Monkey Bars®:
• Lubricate all metallic moving parts as per instructions (flying fox, swing hooks etc). If swings start
to squeek then lubricate swing hooks.
• Check all moving parts including swing seats, ropes, chains and trolleys for wear, rust, or other
deterioration. Replace as needed.
• Owners shall be responsible for maintaining the legibility of any warning labels.
For additional information concerning your Funky Monkey Bars®, please contact our customer service team
or check our website for any important updates. Phone - 1300 912 198 or www.funkymonkeybars.com
Assembly requires 2 adults. Heavy items ! Work on flat level surface.
ASSEMBLY
1. Keep small children away from the Funky Monkey Bars® during assembly.
2. Do not attempt to use the Funky Monkey Bars® until it is completely assembled and every fitting is tight
and secured.
3. Installation typically takes 3-4 hours to complete. Two people are recommended for assembly.
4. Ensure all fittings are tightened to the correct tightening method as described on page 5.
5. Assembly should be carried out on clean, dry, level surface
Please refer to the video section on the Funky Monkey Bars® website for more handy tips and assembly
instructions at http://www.funkymonkeybars.com/pages/videos

LOAD RATING
Page 3
QUALITY & INDEPENDENT TESTING
At Funky Monkey Bars® we take the quality of our designs and safety very seriously. All Funky Monkey Bars® frames
go through a stringent, independent structural testing process prior to being made available for release to our
customers.
Our frames are designed within the parameters of the Australian Standard for Playground Equipment AS4685.1:2014.
The structural integrity of our frames has been tested for performance through a combination of engineering
calculations and physical testing. The tests have been performed by independent, certified structural engineers in
accordance with Australian Standard for Playground Equipment AS4685.1:2014 and European Standards
EN1176-1:2008.
The independent testing conducted on The Orangutan certified the frame to a load rating of 540kgs or 9 users.
N/A
WITNESSED BY:
MODEL
APPROVED BY:
60
9
USER LOAD
(KG)
LOAD TESTING CERTIFICATION
NUMBER
OF USERS
DATE :
COMMENTS:
DATE OF TEST LOAD RATING
(KG)
540
DATE :
I hereby confirm all testing was undertaken in accordance with Physical Testing of Structural Integrity
requirements of AS 4685.1: 2014 App C / EN 1176-1:2008° except where noted below;
Orangutan
Aug 1018
Aug 2018
Funky Monkey Bars® Independent Engineer
Aug 2018

2.0 Metres
clear fall zone
2.0 Metres
clear fall zone
A minimum of 2.0 metres clear fall zone is recommended around
the elevated hanging points of your Funky Monkey Bars®.
(not to scale)
2.0 Metres
clear fall zone
2.0 Metres
clear fall zone
(not to scale)
Page 4
DIMENSIONS
PLAN VIEW
SIDE VIEW
FUNKY MONKEY BARS®
THE ORANGUTAN OVERALL DIMENSIONS
5.05 Metres
2.4 Metres
Varies
3.15 Metres
0.95 M
2.1 Metres
0.95 M
5.05 Metres
3.15 Metres
0.95 M
0.95 M

Page 5
All tubes must be fully inserted
until contact is made with
adjoining tube.
CORRECT INSERTION INTO FITTINGS - (indicative diagram shown)
CORRECT TIGHTENING METHOD OF GRUB SCREWS - (indicative diagram shown)
Gap. No gap.
CLUNK
1. With long end of allen key, hand
tighten grub screw as much as possible.
2. Using other end of the allen key do one full
360 degree turn as a minimum, use muscles!
ASSEMBLY TIPS
o
+ 360
CORRECT TIGHTENING METHOD OF RUNG BOLTS - (INDICATIVE DIAGRAM SHOWN)
1. With long end of allen key, hand tighten bolt
hard up against washer and outside of tube.
Hold rung to avoid rotation.
2. Using short end of the allen key fully tighten,
approximately 3-4 full turns .
o
3-4 turns

Page 6
FIXING TYPICAL ORIENTATION - (indicative drawing shown)
Unless otherwise stated all grub
screws and fittings should face
downwards and outwards. This will
reduce weathering damage, help with
assembly and ease of maintenance.
Check assembly is 100%
level, square & straight.
PLAN VIEW
SIDE VIEW
IT IS CRITICAL YOUR MAIN FRAME IS 100% SQUARE AND LEVEL
(indicative diagram shown)
If your frame is not straight or level remove pegs, loosen
grub screws, re-adjust re-tighten and re-peg the frame.
ASSEMBLY TIPS (continued)
INSTALLATION ON A SLOPE
If your frame is being installed on a slope ensure the monkey
ladder bar is level. Either install at different heights on the legs
or dig down at one end until level.

1x
8mm Allen key
(Included)
10x
Short Tee
D-101
8x
Elbow
D-125
10x
Base Plate
D-131
10x
Peg
1x
Soft Hammer
(Not included)
TOOLS REQUIRED FOR INSTALLATION
FITTINGS
1x
Spirit Level
(Not included)
Page 7
INVENTORY
50Dia. x 900mm
50Dia. x 2950mm
50Dia. x 2300mm
25Dia. x 850mm
50Dia. x 2300mm
4x
Adj. Leg Tube
TUBES
2x
Ladder Tube
2x
Swing Leg Tube
8x
Twirly Tube
13x
Rung Tube
1x
Tape Measure
(Not included)
1x
17mm Rachet
(Not included)
2x
Swing Bar Tube
(short)
50Dia. x 1900mm

4x
Height Sticker
1x
Manufacture Sticker
4x
Plastic End Cap
Page 8
INVENTORY (continued)
27x
M10 Bolt
54x
Rung Insert
27x
Washer
54x
M10 Hex Nut
HARDWARE
COMPONENTS (accessories if applicable)
One of the best things about a Funky Monkey Bar is the ability to add new equipment and
accessories as your child and family grows. You can swap or add accessories to your existing
frame, or add extra frames that will give you more versatility to attach equipment. Check out
what we’ve got in store now at...
WWW.FUNKYMONKEYBARS.COM
4x
Swing Hooks
1x
Trapeze
1x
Sling swing

1x
Ladder Tube
50Dia x 2950mm
RUNG ASSEMBLY (x13)
1
26x
13x
Rung Tube
25Dia x 850mm
9x
Assembled Rungs
from step 1
9x
Rung tube
Hand tighten all bolts.
MONKEY BAR LADDER ASSEMBLY
2
Page 9
ASSEMBLY INSTRUCTIONS - LADDER BAR ASSEMBLY
1. Assemble plastic rung inserts as shown above. 2. Push inserts into both ends of all rungs.
Assemble on flat surface.
9x
M10 Bolts
9x
Washers

FIRMLY TIGHTEN ALL RUNG BOLTS.
1x
Ladder Tube
50Dia x 2950mm
3
4
Hand tighten all bolts
Page 10
ATTACH SECOND LADDER TUBE
9x
M10 Bolts
9x
Washers
o
3-4 turns
18x
See page 5 for correct
tightening method.

LEG ASSEMBLY x 2
5
6
2x
Plastic End Cap
2x
Adj. Leg Tube
50Dia x 2300mm
2x
Assembled Rungs
from step 1
Hand tighten all bolts.
Hand tighten all bolts.
7
Page 11
ASSEMBLY INSTRUCTIONS - LEG ASSEMBLY
INSERT RUNGS
ATTACH SECOND LEG
2x
M10 Bolts
2x
Washers
2x
M10 Bolts
2x
Washers
Insert plastic end caps into leg tubes.
IF YOU HAVE A CARGO NET PLEASE REFER TO AND FOLLOW - CARGO NET ASSEMBLY INSTRUCTIONS, PAGE 9

8
9
Tighten all grub screws.
Hand tighten grub screws.
Temporary location.
1x
2x
Base Plate
D-125
1x
Short Tee
D-101
Page 12
ATTACH BASE PLATES
SLIDE ON SHORT TEE (a)
A

10
11
200mm
Tallest user + 200mm.
Good starting height is
100-200mm above reach.
Position short-tee at measured height.
2x
Height Sticker
2x
2x
Short Tee
D-101
Page 13
APPLY HEIGHT STICKERS.
SET LADDER BAR HEIGHT.

REPEAT STEPS 5-12 FOR 1x MORE LEG ASSEMBLY.
SAME PROCEDURE BUT SHORT TEE A PLACED ON OTHER LEG- (see step 14 for final result)
Leg assembly 2 with short tee (A) located on other leg
and 2x short tees at top positioned at the same
set height from step 11.
2
A
13
12
Page 14
FIRMLY TIGHTEN ALL GRUB SCREWS & RUNG BOLTS.
4x
+ 360
o
Fully Tighten rung bolts.
o
3-4 turns
Hand tighten grub screw A.(short tee)
(Temporary location). Fully
tighten all others.
A
4x
3x
Short Tee
D-101
1

Height set step 11
Approx 950mm
15
Firmly tighten all grub screws and bolts,
Leave short tee A loose.
CHECK ALL FITTING GRUB SCREWS AND RUNG BOLTS ARE FULLY TIGHTENED
+ 360
o
14 LEG ASSEMBLY x2.
Page 15
Standing up with top tees
facing each other.
Check all grub screws are fully tightened.
Leave short tee (A) hand tight only.
1
2
A
A

Tighten all grub screws.
16
17
18
19
1x
Twirly Tube
50Dia x 900mm
1x
Elbow
D-125
1x
Base Plate
D-131
ASSEMBLE VERTICAL TWIRLY TUBE
+ 360
o
Page 16
ASSEMBLY INSTRUCTIONS - TWIRLY WHIRLY BAR ASSEMBLY
ATTACH HORIZONTAL TWIRLY TUBE
Fully insert twirly tube then
firmly tighten all grub screws.
1x
Twirly Tube
50Dia x 900mm
TWIRLY WHIRLY BAR x4
REPEAT STEPS 16 - 17 FOR 3 MORE TWIRLY WHIRLY BARS.
Insert Twirly Tube fully into Elbow.
CLUNK

20 FLIP LEGS 1 & 2 OVER
180º
21
+ 360
o
1. Attach first set of legs 1 - tighten all grub screws.
2. Attach second set of legs 2 - tighten all grub screws.
ATTACH 2x LEGS TO LADDER
Page 17
180º
12
1
2
ASSEMBLY INSTRUCTIONS - MAIN MONKEY BAR ASSEMBLY
For the following step the
legs should be flipped
over & attached
one at a time.

4x
Pegs
22
Select suitable location.
Hammer in pegs x4.
23
Page 18
FLIP ASSEMBLY OVER
SECURE TO GROUND
CRITICAL : ENSURE YOUR FRAME IS 100% SQUARE AND LEVEL (AS PER PAGE 6)
BEFORE MOVING ONTO THE REST OF THE ASSEMBLY
180º

825mm
500mm
1. Position short tees approx.
825mm away from elbows.
2. Center swing hooks - (if applicable)
on remaining length of swing bar tube.
On flat level ground slide on all fittings and fully tighten elbow grub screws
Leave short tees and swing hooks loose for assembly adjustment.
Rotate swing bars into ready position
& roughly locate fittings as shown.
24
25 2x ASSEMBLED SHORT SWING BARS
Page 19
90º
90º
4x
Swing Hooks
2 x
Short Tee
D-101
2x
Elbow
D-125
2x
Swing Bar Tube
(short)
ASSEMBLE SHORT SWING BARS
1
2
1
2
ASSEMBLY INSTRUCTIONS - SWING BAR AND LEG ASSEMBLY