zarges Skymaste Industrial Z600 Parts list manual

Assembly and
usage instructions
www.zarges.de
Z600 brace-free mobile scaf-
fold towers

Assembly and usage instructions
Z600 brace-free mobile scaffold towers 3
Z600
Table of contents
1. General information 4
1.1. Introduction 4
1.2. Manufacturer 4
1.3. Type approval 4
1.4. Warranty 4
1.5. Date of issue 5
1.6. Copyright and trademark rights 5
1.7. Intended use 5
1.8. Improper use 5
2. Assembly 6
2.1. Safety provisions 6
2.2. Working on electrical units with the scaffold tower 8
2.3. Other applicable safety instructions 8
2.4. Technical data 8
2.5. General assembly regulations 8
2.6. Basic dimensions 12
 2.7.Identication 13
2.8. Parts list incl. ballast (see also 5.2) 14
2.9. Position of the single parts 16
2.10. Assembly drawings 17
3. Note on dismantling the scaffold tower 21
4. Usage regulations 21
5. Structural safety regulations 22
5.1. General information 22
5.2. Attaching the ballast 22
5.3. Maintenance, servicing, storage and cleaning 22
5.4. Testing the scaffold components 23
6. Spare parts 24
7. Accessories 25
Notes 28

Assembly and usage instructions
Z600 brace-free mobile scaffold towers
4
1. General information
1.1. Introduction
These assembly and usage instructions apply exclusively to the scaffold towers described in
these usage and assembly instructions.
The notes on safety and the rules and regulations for handling scaffold towers cover the scaffold
towers referred to in this documentation.
Operators bear sole responsibility for:
• ensuring adherence to the local, regional and national regulations,
• observance of the regulations (laws, ordinances, guidelines etc.) for safe handling
listed in the assembly and usage instructions,
• ensuring that the assembly and usage instructions are available to operating
personnel and that the instructions, information, warnings and safety provisions they
contain are followed to the letter.
1.2. Manufacturer
The manufacturer of the scaffold towers described in this documentation is
ZARGES GmbH & Co. KG Tel.: 08 81 / 68 71 00
Access technology division Telefax: 08 81 / 68 72 95
P.O. Box 16 30 E-mail: [e-mail]
82360 Weilheim Internet: http://www.zarges.de
1.3. Type approval
All single parts are tested by TÜV-Product Service. The all-
in-one scaffold towers listed here are tested for structural
stability.
1.4. Warranty
The scope and period of the warranty type are dened in
the manufacturer's sales and delivery conditions. The assembly and usage instructions valid
atthetimeofdelivery(seeSection1.5)applytoallwarrantyclaimsarisingfrom insufcient
documentation. The following applies above and beyond the sales and delivery conditions:
The manufacturer accepts no liability for damage to the scaffold towers arising from one of
more of the following:
• Ignorance of or failure to observe these assembly and usage instructions
• Insufcientlyqualiedorinstructedoperatingpersonnel
• Failure to use original spare parts.
The operator bears sole responsibility for ensuring
• thatthesafetyprovisionsasdenedinSection5areadheredto,
• that improper use (see Section 1.8), faulty erection and unauthorised operation are
ruled out and
• that above and beyond this, intended use (see Section 1.7) is ensured and that the
scaffoldtowersareoperatedinaccordancewiththeapplicationconditionsdenedin
the contract.

Assembly and usage instructions
Z600 brace-free mobile scaffold towers 5
Z600
1.5. Date of issue
The date of issue of these English assembly and usage instructions is 01 January 2008.
1.6. Copyright and trademark rights
• The copyright to these assembly and usage instructions lies with the manufacturer.
• The manufacturer also reserves all further rights, in particular in the case of
the granting of a patent or utility patent registration.
• Any infringement of the conditions described above will result in liability for
damages!
1.7. Intended use
The scaffold towers listed in these assembly and usage instructions may only be used as scaffold
towers in accordance with EN 1004 and the overview of models contained in these assembly and
usage instructions.
1.8. Improper use
Misuse - that is, any use of the scaffold towers documented in these assembly and usage
instructions which deviates from that described in Section 1.7 - shall be deemed improper use as
denedbytheProductSafetyAct(status1.8.1997).Thisalsoappliestodisregardofthestandards
and guidelines listed in these assembly and usage instructions.

Assembly and usage instructions
Z600 brace-free mobile scaffold towers
6
2. Setup
2.1. Safety provisions
1. The stipulations of EN 1004 “Mobile work platforms” apply to the structural safety,
erection and use of the aforementioned scaffold towers.
2. The scaffold towers may only be set up and used by persons familiar with these
assembly and usage instructions.
3. Atleasttwopersonsarerequiredtosetupordismantlethescaffoldtower.
4. Undamagedand fault-free original spareparts forthemanufacturer's
scaffolding system to which the test certicate applies must be
used. Before using the scaffold tower, all parts must be examined
for correct assembly and functionality.
5. The maximum platform heights as dened by EN 1004 are
8 m outdoors and 12 m in fully enclosed spaces. For the
scaffold towers described in these assembly and usage
instructions, the maximum platform height in fully enclosed
spaces is 10 m.
6. The use of lifting tackle on the scaffold tower is not permissible.
7. Therstplatformmustnotbemorethan4.40maboveoorlevel.Thedistancebetween
further platforms must not exceed 4 m. The platforms must be at least 1.70 m apart.
8. When setting up or dismantling scaffold towers, platforms or scaffold planks must be
laid out over the entire area at a distance of 2 m as an aid to assembly/dismantling.
Where scaffold planks are used, they must extend 500 mm beyond the scaffold tower
on each side. Standing on railings and braces is prohibited, even during setup and
dismantling.
9. The scaffold tower may only be set up in vertical
positiononahorizontal,levelsurfaceofsufcientload-
bearing capacity. Where necessary, load-distributing
pads must be used.
10. Chassis beams, ballast weights, stabilisers and stand-off brackets must be used to
ensure structural safety as described in these assembly and usage instructions.
11. Working on the work platform is only permissible with full protection on 3 sides,
i.e. guard-rail frame, knee protection and peripheral toeboards. Toeboards are not
necessary on the rest platforms.
12. Working on several work platforms simultaneously is prohibited.

Assembly and usage instructions
Z600 brace-free mobile scaffold towers 7
Z600
13. When setting up the scaffold tower alongside a wall, stand-off brackets (accessories,
Order No. 42920) can be used in addition to ballast.
14. The maximum load-bearing capacity of the scaffold tower with an evenly distributed
load is 2.0 kN/m² (in accordance with EN 1004 - scaffolding category 3).
15. All swivel castors must be locked in position by pressing down the
brake levers. The brake levers may only be released in order to move
the scaffold tower.
16. There must be no persons, tools or material on
the platform when the scaffold tower is moved.
Any impact must be avoided. The scaffold tower
may only be moved by hand, in longitudinal or
diagonaldirectionandonarm,levelsurfacefreeof
obstacles. The scaffold tower must not be moved at
more than normal walking speed.
17. Vehicles (e.g. fork lifts) must not be used to move the scaffold tower. The scaffold tower
must not be lifted, pulled or pushed using a fork lift.
18. The surface on which the scaffold tower is moved must be capable of bearing its
weight.
19. Where the scaffold tower is used outdoors or
in open buildings, it must be moved to a wind-
sheltered position or secured against tipping over
by other suitable means (e.g. anchors) at wind
strengths exceeding 6 (on the Beaufort scale), at
theonsetofastormandwhennishingworkfor
the day. When wind strengths exceed 6 (12 m/s), it
becomesperceptiblydifculttowalk.
20. When using anchors in combination with dowel connections, follow the instructions
in the “Infosheet for attaching dowels for anchoring building scaffolding” (available
from Carl Heymanns Verlag KG, Luxemburger Straße 449 in 50939 Cologne -Order
No. ZH 1/500).
21. The use of planks etc. to bridge gaps between
scaffolding and buildings is not permissible.
The scaffold tower must not be used as a stair tower
to reach other constructions.
22. Before using the scaffold tower, check that it is in vertical position and correct its
alignment if necessary. The scaffold tower must also be checked for correct and
complete setup as described in Section 2.8.
23. When using stabilisers, they must be attached beneath a rung. The stabiliser turning
locks must always be attached.

Assembly and usage instructions
Z600 brace-free mobile scaffold towers
8
2.2. Working on electrical units with the scaffold tower
The scaffold tower must not be used to perform work on or in the vicinity of unprotected live
units unless
• thesectionoftheunitinquestionhasbeendisconnected,
• thesectionoftheunitinquestionhasbeensecuredagainstbeingswitchedbackon,
• thesectionoftheunitinquestionhasbeencheckedtoensurethatitisnotlive,
• thesectionoftheunitinquestionhasbeenshort-circuitedwithagroundingbarand
• thesectionoftheunitinquestionhasbeenshieldedagainstadjacentliveparts.
2.3. Other applicable safety instructions
The scaffold tower must be tested, set up and used in accordance with the stipulations of
• BGI 663 (employers' liability insurance association, building construction) " Instructions
for handling work and safety scaffolds."
BGR165andBGI594(formerlyZH1/228)"Safetyrulesfortheuseofelectricalequipmentinthe
caseofincreasedelectricalhazard"applywhenusingelectricalequipmentonthescaffoldtower.
2.4. Technical data
Brace-free scaffold tower, normal version 0.75 m x 1.8 m / 2.5 m / 3.0 m
Approved in accordance with EN 1004 Scaffolding category 3
Permissible load in acc. with scaffolding category 3 200 kg/m²
Maximum total scaffolding load 270 kg / 375 kg / 450 kg
Maximum platform load 270 kg / 375 kg / 450 kg
Maximum platform height 8.40 m
Maximum scaffold height 9.40 m
Maximum working height 10.40 m
Brace-free mobile scaffold tower, wide version 1.35 m x 1.8 m / 2.5 m / 3.0 m
Approved in accordance with EN 1004 Scaffolding category 3
Permissible load in acc. with scaffolding category 3 200 kg/m²
Maximum total scaffolding load 486 kg / 675 kg / 810 kg
Maximum platform load 486 kg / 675 kg / 810 kg
Maximum platform height 8.40 m
Maximum scaffold height 9.40 m
Maximum working height 10.40 m

Assembly and usage instructions
Z600 brace-free mobile scaffold towers 9
Z600
2.5. General assembly regu-
lations
1. Fit the swivel castor with
height adjuster on push-on
end frame
Fig. 1.
3. Fit stabilisers
To ensure structural safety,
the upper coupling of the
stabilisers must be attached
under the rung (6th or 7th
rung from the bottom). It is
also essential to ensure that all
stabilisers have contact with
the ground!
Fig. 3. Fig. 4.
5.
Fit the platform diagonals
Always attach the two platform
diagonals directly above the
4th rung from the bottom. The
platform diagonals are always
attached from the inside to the
outside.
Fig. 5. Fig. 6.
Fig. 10.
Fig. 2.
î
é1.
2.
é
î
é
1.
2.
é
2. Attach auxiliary railings
To facilitate assembly, the two
railings are attached to the two
push-on end frames. When
assembly has been completed,
they are removed and returned
to their original position.
é
1.
Fig. 7.
4. Fit further push-on end
frames.
é
2.
!
î
Fig. 8.
Fig. 9.
!

Assembly and usage instructions
Z600 brace-free mobile scaffold towers
10
8. Fit the platforms
Scaffold planks or platforms
must be installed as assembly
aids. The platform is used as
a standing area while carrying
out further assembly steps (cf.
Section 2.1 No. 7). All assembly
aids (scaffold planks etc.) must
be removed when the scaffold
tower has been fully assembled.
Fig. 14. Fig. 15.
êê
1. 2.
3.
max.
0.5m ì
10. Fit guard-rail frame
(topmost platform) Fig. 17.
ê
ê
9. Fit railings to rest platform
(only on scaffold towers with
a working height exceeding
7.60m)
Fig. 16.
é
ê
7. Align the scaffold tower
After setting up the basic
module, it must be aligned
using a spirit level. If the scaf-
fold tower is rst assembled
and then moved to its place
of deployment, it is essential
to check the alignment again
once it is in position.
Fig. 13.
6. Fit the diagonal braces
The diagonal braces are in-
serted as described in Chapter
2.10, depending on the scaffold
height.
Fig. 11. Fig. 12.
é

Assembly and usage instructions
Z600 brace-free mobile scaffold towers 11
Z600
Fig. 20. Fig. 21.
12. Fit the toeboards
(side toeboard, end toeboard)
1.
2.
îêê
13. Fit the wall anchor
Important note!
Before climbing onto the scaffold tower, please
check again that it is aligned horizontally and that
all four stabilisers have ground contact, as this is
essential for stability.
Fig. 21.
11. Fit railings to work plat-
form
Remove auxiliary railings from
Point 2 and insert at the top.
Railings are attached from the
inside to the outside.
Warning!: with the claws
pointing outwards, snap into
place in the push-on end frames
and guard-rail frames.
Fig. 18.
îî
Fig. 19.

Assembly and usage instructions
Z600 brace-free mobile scaffold towers
12
2.6. Basic dimensions
Width 0.75m 1.35m
Length 1.8m 2.5m 3.0m 1.8m 2.5m 3.0m
a1.8m 2.5m 3.0 1.8m 2.5m 3m
b0.75m 0.75m 0.75m 1.35m 1.35m 1.35m
c2.5m 2.5m 2.5m 3.25m 3.25m 3.25m
d2.8m 3.5m 4.0m 2.8m 3.5m 4.0m
a
b
c
d
45°

Assembly and usage instructions
Z600 brace-free mobile scaffold towers 13
Z600
2.7. Identication
Art. No.
Type plate
max. platform height
max. perm. load
EAN code

Assembly and usage instructions
Z600 brace-free mobile scaffold towers
14
Brace-free mobile scaffold tower, normal version
Scaffold size Working height 1) Parts list Push-on end frame 1 m Push-on end frame 2 m Guard-rail frame 1 m Railing Trapdoor platform End toeboard Side toeboard Diagonal brace Platform diagonal Triangular stabiliser Swivel castor Ø200 mm Stirrup step
Ballast
Indoor use
Outdoor use
approx. [m] Order
No.
42905 42904 42906 42955 42931 42913 42943 42937 42978 42926 42917 42940
0.75 x 1.8
5.80 52030 222212222441
Number of ballast weights per swivel castor; attachment to stabiliser
0 0
6.45 52040 -42212242441 00
7.60 52050 242422242441 00
8.40 52060 -62422262441 02
9.55 52070 262422282441 17
10.40 52080 -82422282441 1X
approx. [m] Order
No.
42905 42904 42906 42956 42910 42913 42914 42908 42979 42926 42917 42940
42912
0.75 x 2.5
5.80 52130 222212222441 00
6.45 52140 -42212242441 00
7.60 52150 242422242441 00
8.40 52160 -62422262441 01
9.55 52170 262422282441 05
10.40 52180 -82422282441 1X
approx. [m] Order
No.
42905 42904 42906 42957 42933 42913 42944 42938 42980 42926 42917 42940
42912
0.75 x 3.0
5.80 52230 222212222441 00
6.45 52240 -42212242441 00
7.60 52250 242422242441 01
8.40 52260 -62422262441 08
9.55 52270 262422282441 0X
10.40 52280 -82422282441 0X
1)Withmax.height-adjustedswivelcastors42917(adjustablerange:0.30m)
Observe ballasting regulations in the assembly and usage instructions!
X: not permissible!
2.8. Parts list incl. ballast (see also 5.2)

Assembly and usage instructions
Z600 brace-free mobile scaffold towers 15
Z600
Brace-free mobile scaffold tower, wide version
Scaffold size Working height 1) Parts list Push-on end frame 1 m Push-on end frame 2 m Guard-rail frame 1 m Railing Trapdoor platform Platform without trapdoor End toeboard Side toeboard Diagonal brace Platform diagonal Triangular stabiliser Swivel castor Ø200 mm Stirrup step
Ballast
Indoor use
Outdoor use
approx. [m] Order
No.
42902 42901 42903 42955 42931 42932 42911 42943 42937 42978 42926 42917 42940
1.35 x 1.8
5.80 52330 2222112222441
Number of ballast weights per swivel castor; attachment to stabiliser
0 0
6.45 52340 -422112242441 00
7.60 52350 2424222242441 01
8.40 52360 -624222262441 02
9.55 52370 2624222282441 03
10.40 52380 -824222282441 0X
approx. [m] Order
No.
42902 42901 42903 42956 42910 42930 42911 42914 42908 42979 42926 42917 42940
42912
1.35 x 2.5
5.80 52430 2222112222441 00
6.45 52440 -422112242441 00
7.60 52450 2424222242441 00
8.40 52460 -624222262441 00
9.55 52470 2624222282441 02
10.40 52480 -824222282441 0X
approx. [m] Order
No.
42902 42901 42903 42957 42933 42934 42911 42944 42938 42980 42926 42917 42940
42912
1.35 x 3.0
5.80 52530 2222112222441 00
6.45 52540 -422112242441 00
7.60 52550 2424222242441 00
8.40 52560 -624222262441 00
9.55 52570 2624222282441 0X
10.40 52580 -824222282441 0X
1)Withmax.height-adjustedswivelcastors42917(adjustablerange:0.30m)
Observe ballasting regulations in the assembly and usage instructions!
X: not permissible!

Assembly and usage instructions
Z600 brace-free mobile scaffold towers
16
2.9. Position of the single parts
Stirrup step
Trapdoor platform
End toeboard
Side toeboard
Diagonal brace
Stabiliser
Railing
Push-on end frame 2 m
Push-on end frame 1 m
Guard-rail frame 1 m
Platform diagonal

Z600
Assembly and usage instructions
Z600 17
Order No. 52030
Scaffold size 0.75x1.80m
Working height 5.80m
Scaffold height 4.80m
Platform height 3.80m
Weight 130.6kg
Order No. 52130
Scaffold size 0.75x2.50m
Working height 5.80m
Scaffold height 4.80m
Platform height 3.80m
Weight 140.7kg
Order No. 52230
Scaffold size 0.75x3.00m
Working height 5.80m
Scaffold height 4.80m
Platform height 3.80m
Weight 152.1kg
Order No. 52040
Scaffold size 0.75x1.80m
Working height 6.45m
Scaffold height 5.45m
Platform height 4.45m
Weight 141.2kg
Order No. 52140
Scaffold size 0.75x2.50m
Working height 6.45m
Scaffold height 5.45m
Platform height 4.45m
Weight 152.1kg
Order No. 52240
Scaffold size 0.75x3.00m
Working height 6.45m
Scaffold height 5.45m
Platform height 4.45m
Weight 164.3kg
Order No. 52050
Scaffold size 0.75x1.80m
Working height 7.60m
Scaffold height 6.60m
Platform height 5.60m
Weight 172.8kg
Order No. 52150
Scaffold size 0.75x2.50m
Working height 7.60m
Scaffold height 6.60m
Platform height 5.60m
Weight 190.4kg
Order No. 52250
Scaffold size 0.75x3.00m
Working height 7.60m
Scaffold height 6.60m
Platform height 5.60m
Weight 210.4kg
2.10. Assembly drawings

Assembly and usage instructions
Z600
18
Order No. 52060
Scaffold size 0.75x1.80m
Working height 8.40m
Scaffold height 7.40m
Platform height 6.40m
Weight 183.4kg
Order No. 52160
Scaffold size 0.75x2.50m
Working height 8.40m
Scaffold height 7.40m
Platform height 6.40m
Weight 201.8kg
Order No. 52260
Scaffold size 0.75x3.00m
Working height 8.40m
Scaffold height 7.40m
Platform height 6.40m
Weight 222.6kg
Order No. 52070
Scaffold size 0.75x1.80m
Working height 9.55m
Scaffold height 8.55m
Platform height 7.55m
Weight 196.6kg
Order No. 52170
Scaffold size 0.75x2.50m
Working height 9.55m
Scaffold height 8.55m
Platform height 7.55m
Weight 215.8kg
Order No. 52270
Scaffold size 0.75x3.00m
Working height 9.55m
Scaffold height 8.55m
Platform height 7.55m
Weight 237.4kg
Order No. 52080
Scaffold size 0.75x1.80m
Working height 10.40m
Scaffold height 9.40m
Platform height 8.40m
Weight 202.0kg
Order No. 52180
Scaffold size 0.75x2.50m
Working height 10.40m
Scaffold height 9.40m
Platform height 8.40m
Weight 221.2kg
Order No. 52280
Scaffold size 0.75x3.00m
Working height 10.40m
Scaffold height 9.40m
Platform height 8.40m
Weight 242.8kg

Z600
Assembly and usage instructions
Z600 19
Order No. 52330
Scaffold size 1.35x1.80m
Working height 5.80m
Scaffold height 4.80m
Platform height 3.80m
Weight 157.1kg
Order No. 52430
Scaffold size 1.35x2.50m
Working height 5.80m
Scaffold height 4.80m
Platform height 3.80m
Weight 172.0kg
Order No. 52530
Scaffold size 1.35x3.00m
Working height 5.80m
Scaffold height 4.80m
Platform height 3.80m
Weight 188.0kg
Order No. 52340
Scaffold size 1.35x1.80m
Working height 6.45m
Scaffold height 5.45m
Platform height 4.45m
Weight 170.5kg
Order No. 52440
Scaffold size 1.35x2.50m
Working height 6.45m
Scaffold height 5.45m
Platform height 4.45m
Weight 186.2kg
Order No. 52540
Scaffold size 1.35x3.00m
Working height 6.45m
Scaffold height 5.45m
Platform height 4.45m
Weight 203.0kg
Order No. 52350
Scaffold size 1.35x1.80m
Working height 7.60m
Scaffold height 6.60m
Platform height 5.60m
Weight 218.6kg
Order No. 52450
Scaffold size 1.35x2.50m
Working height 7.60m
Scaffold height 6.60m
Platform height 5.60m
Weight 245.8kg
Order No. 52550
Scaffold size 1.35x3.00m
Working height 7.60m
Scaffold height 6.60m
Platform height 5.60m
Weight 275.0kg

Assembly and usage instructions
Z600
20
Order No. 52360
Scaffold size 1.35x1.80m
Working height 8.40m
Scaffold height 7.40m
Platform height 6.40m
Weight 232.0kg
Order No. 52460
Scaffold size 1.35x2.50m
Working height 8.40m
Scaffold height 7.40m
Platform height 6.40m
Weight 260.0kg
Order No. 52560
Scaffold size 1.35x3.00m
Working height 8.40m
Scaffold height 7.40m
Platform height 6.40m
Weight 290.0kg
Order No. 52370
Scaffold size 1.35x1.80m
Working height 9.55m
Scaffold height 8.55m
Platform height 7.55m
Weight 249.0kg
Order No. 52470
Scaffold size 1.35x2.50m
Working height 9.55m
Scaffold height 8.55m
Platform height 7.55m
Weight 277.8kg
Order No. 52570
Scaffold size 1.35x3.00m
Working height 9.55m
Scaffold height 8.55m
Platform height 7.55m
Weight 308.6kg
Order No. 52380
Scaffold size 1.35x1.80m
Working height 10.40m
Scaffold height 9.40m
Platform height 8.40m
Weight 257.2kg
Order No. 52480
Scaffold size 1.35x2.50m
Working height 10.40m
Scaffold height 9.40m
Platform height 8.40m
Weight 286.0kg
Order No. 52580
Scaffold size 1.35x3.00m
Working height 10.40m
Scaffold height 9.40m
Platform height 8.40m
Weight 316.8kg