Backyard Play Systems 4500 Assembly Manual Download Page 20 | Manualshive

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18

FORT WITH MONKEY BAR OPTION

SIDE WALLS

MONKEY BAR / LEFT SIDE

SWING SIDE

IF YOU HAVE MONKEY BARS, YOUR SIDE WALLS WILL BE CONSTRUCTED AS BELOW.

IF YOU

DO NOT

HAVE MONKEY BARS, YOUR SIDE WALLS WILL BE CONSTRUCTED AS BELOW.

STOP

SIDE WALLS

LEFT SIDE

SWING SIDE

CONTINUE TO PAGE 22.

CONTINUE TO PAGE 19.

BALLUSTERS INSTALLED

NO BALLUSTERS INSTALLED

FORT WITHOUT MONKEY BAR OPTION

IMPORTANT!

IMPORTANT!

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Summary of Contents for 4500

Page 1: ...H CTOBER TO 0 34 3ATURDAY TO 0 34 OVEMBER THROUGH ARCH TO 0 34 ELPFUL INT 4O HELP MAKE THE ASSEMBLY OF YOUR PLAYSET EASIER USE THIS ALL IN ONE PLAYSET INSTRUCTION MANUAL LL OTHER MANUALS PACKED IN SOM...

Page 2: ...This page intentionally left blank...

Page 3: ...16 Combination Wrench 2 Square Drive Bit included Phillips Bit Combo Drive Bit Cordless Drill w Charger 1 8 Drill Bit 1 4 Drill Bit Tape Measure Level C Clamps 8 Step Ladder Customer Service 1 866 890...

Page 4: ...2 This page intentionally left blank...

Page 5: ...hen back out the bolt and install with specified washers Due to wood characteristics and the manufacturing process hex bolts may protrude past a surface If this condition occurs add additional supplie...

Page 6: ...children not to climb when the equipment is wet Slippery surfaces may cause a hazard Verify that suspended climbing ropes chain or cable are secured at both ends Verify that suspended climbing ropes...

Page 7: ...members Reinstall any plastic parts such as swing seats or any other items that were removed for the cold season Rake and check depth of loose fill protective surfacing materials to prevent compaction...

Page 8: ...772 Check and maintain the depth of the loose fill surfacing material To maintain the right amount of loose fill materials mark the correct level on play equipment support posts That way you can easil...

Page 9: ...SET ORIENTATION Hint Throughout this manual references made to the Left Side the Right Side and the Front of the playset serve as a consistent reminder to help with assembly RIGHT SIDE FRONT SIDE LEFT...

Page 10: ...e is to first drill through a 1 4 pilot hole from the Hex Bolt side and then drill the larger 1 2 hole from the opposite T Nut side This will help avoid splintering the wood The Drill Both Sides ICON...

Page 11: ...SIZE CONVERSION CHART Nominal Board Size Actual Size 1 x 4 3 4 x 3 3 8 1 x 6 3 4 x 5 3 8 5 4 x 4 1 x 3 1 2 5 4 x 6 1 x 5 1 2 2 x 4 1 3 8 x 3 3 8 2 x 6 1 3 8 x 5 3 8 4 x 4 3 1 4 x 3 1 4 x2 x1 2 x 6 x 7...

Page 12: ...ing Clip Swing Hanger Plaque x6 x1 x6 Sling Swing Safety Handle x1 Green x2 Yellow x3 x3 x13 x1 Rope Climbing Rocks Slide x6 Plastic Hole Plug Angled x4 x26 Angle plug 2035 2004 2014 2023 2003 2000 20...

Page 13: ...R 3 8 LAG BOLT WOODSCREWS 3 8 LOCK NUT 4 3 1 2 3 8 2 1 2 3 1 1 4 2 1 2 PAN HEAD SCREW 2 1 2 1 5 8 x11 3 8 ACORN NUT 3 8 x8 x3 x87 x46 x4 x8 x142 x49 x30 x245 x3 x6 x107 x26 1 4 ROCK WALL HARDWARE T Nu...

Page 14: ...12 5 16 LAG BOLT 3 x8 5 16 FLAT WASHER 5 16 LOCK WASHER 5 16 5 16 x8 x8 3 8 5 1 4 3 1 2 4 3 8 3 3 4 3 8 3 8 2 1 2 3 8 3 3 8 5 1 2 3 8 3 8 10 x4 x1 x19 x4 x6 x16 x2 x2 A C T U A L S I Z E S H O W N...

Page 15: ...13 ACCESSORIES PARTS LIST Spring Clip x1 x1 Tire Chains Quick Clip x3 x3 Tire Swing Hanger x1 x1 Telescope Steering Wheel x1 2073 2020 2011 2008 A 2004 2018 2120...

Page 16: ...L S I Z E S H O W N 3 8 FLAT WASHER 3 8 3 8 LOCK NUTS 3 8 3 8 ACORN NUT 3 8 x1 1 4 STEERING WHEEL HDW Lag Screw Flat Washer 1 1 2 1 1 4 x2 2 3 4 3 8 x2 3 8 x 2 3 4 BUTTON HD SCREW 3 8 FENDER WASHER 3...

Page 17: ...P SWING ROCK WALL LEFT SIDE SWING SIDE FRONT SIDE BACK SIDE SLIDE ORIENTATION 16 3 6 SAFETY AREA 6 SAFETY AREA 20 1 11 1 HEIGHT 28 3 32 1 SET UP ORIENTATION LEFT SIDE SWING SIDE FRONT SIDE SWING ROCK...

Page 18: ...Lay Out Corner Posts as shown Orient the 2 holes of 1033 MS UP x2 2 x 4 x 75 1 2 1001 MS x2 2 x 4 x 75 1 2 1001 MS x2 3 x 3 x 44 1 8 2310 MS x2 3 x 3 x 44 1 8 2310 MS x8 5 4 x 6 x 47 3 4 1029 MS x4 5...

Page 19: ...side corner post assemblies as shown T Nut x12 Pre fit deck boards so they are evenly spaced before installing screws End deck boards are flush at edge of floor support x8 5 4 x 6 x 47 3 4 1029 MS x4...

Page 20: ...S YOUR SIDE WALLS WILL BE CONSTRUCTED AS BELOW IF YOU DO NOT HAVE MONKEY BARS YOUR SIDE WALLS WILL BE CONSTRUCTED AS BELOW STOP SIDE WALLS LEFT SIDE SWING SIDE CONTINUE TO PAGE 22 CONTINUE TO PAGE 19...

Page 21: ...4 Wood Screws x16 Use 2324 MS as a 3 1 4 spacer x6 5 8 x 3 1 4 x 34 1 2 2324 MS 3 1 4 3 1 4 Ensure 3 1 4 space between each baluster x1 1 x 4 x 56 1 2 1037 MS x1 1 x 4 x 56 1 2 1037 MS x2 5 8 x 3 1 4...

Page 22: ...s x8 TOP Flush 1 1 4 Wood Screws x24 Use 2324 MS as a 3 1 4 spacer x6 5 8 x 3 1 4 x 34 1 8 2324 MS 3 1 4 3 1 4 Ensure 3 1 4 space between each baluster x1 1 x 4 x 56 1 2 1037 MS x1 1 x 4 x 56 1 2 1037...

Page 23: ...21 STOP SIDE WALLS LEFT SIDE SWING SIDE Use two 2 3 Wood Screws Flush 3 Wood Screws x 16 Flush FORT WITHOUT MONKEY BAR OPTION YOU MAY NOW CONTINUE REGULAR ASSEMBLY OF YOUR PLAYSET ON PAGE 24...

Page 24: ...1 4 Wood Screws x16 Use 2324 MS as a 3 1 4 spacer x6 5 8 x 3 1 4 x 34 1 2 2324 MS 3 1 4 3 1 4 Ensure 3 1 4 space between each baluster x1 1 x 4 x 56 1 2 1037 MS x1 1 x 4 x 56 1 2 1037 MS x2 5 8 x 3 1...

Page 25: ...Wood Screws x 16 Flush x1 1 x 4 x 56 1 2 1037 MS x1 1 x 4 x 56 1 2 1037 MS YOU MAY NOW CONTINUE REGULAR ASSEMBLY OF YOUR PLAYSET STOP ATTENTION MONKEY BAR OPTION OWNERS LEFT SIDE WALL IS SHOWN WITH BA...

Page 26: ...ck Washer Flat Washer SWING SIDE UPPER ARMS LEFT SIDE x1 2 x 4 x 51 1009 MS x1 2 x 6 x 84 1088 MS 1 4 Pre Drill all holes 1 1 2 DEEP Do not drill through DO NOT OVER TIGHTEN LAG BOLTS Install bolts fi...

Page 27: ...fety two people are required to carefully roll fort over FORT Temporarily secure two Right Side Legs 2325 MS with 5 1 4 Hex Bolts Tap Bolts down lightly until Bolts bottom out Do not install T Nuts at...

Page 28: ...ews x 26 Two in each deck board SAME MEASUREMENT SAME MEASUREMENT SIDE VIEW Hex Bolt Lag Bolt T Nut x1 2 x 6 x 84 1088 MS x1 2 x 4 x 51 1009 MS x1 5 4 x 6 x 67 1 2 1085 MS 1 4 Pre Drill all holes 1 1...

Page 29: ...And Tighten Into T Nuts At This Time After tightening all bolts Gently return Playset to it s upright position Move partially assembled Playset into it s permanent location at this time making sure g...

Page 30: ...s shown 3 Wood Screw RIGHT SIDE BACK SIDE Flush FORT STEP LADDER Back side of ladder Mark and drill 9 16 through part 1009 MS Angled End 2 1 2 Wood Screws x 22 Back Front Flush POSITION LADDER TOP BLO...

Page 31: ...1200 MS x4 5 4 x 4 x 19 7 16 1199 MS FORT STEP LADDER 4 1 4 Hex Bolt 3 Wood Screws x6 Lock Washer Flat Washer T Nut Flush Position Ladder Top Block beneath Deck End Board Attach with three 1 5 8 Wood...

Page 32: ...30 SWING BEAM 3 Lag Screw x24 Lock Washer x24 Flat Washer x24 SWING HANGERS ANGLE BRACKETS SWING BEAM 3 1 2 Hex Bolt Flat Washer Flat Washer Lock Nut x2 2023 x6 2003 2 3 4 x 5 3 8 x 94 1 2 x1 2314 MS...

Page 33: ...er 5 16 Flat Washer Pre drill 3 16 x 2 DEEP pilot holes Install fasteners 2106 H x1 Step 1 Step 2 Step 3 x1 2106 H Orient swing beam as shown DO NOT OVER TIGHTEN LAG BOLTS A FRAME ASSEMBLE T Nut x4 x2...

Page 34: ...installed T Nuts are underneath Add extra Flat Washers if bolt threads protrude past T Nuts A FRAME INSTALL Two people are needed to raise and steady Swing Beam and A Frame 4 Hex Bolt Flat Washer x1...

Page 35: ...33 A FRAME INSTALL Pre drill four 3 16 pilot holes 2 DEEP Drill holes must be 3 16 2 DEEP IMPORTANT 5 16 x 3 Lag Bolt 5 16 Lock Washer 5 16 Flat Washer x4 A FRAME INSTALL...

Page 36: ...EAM SUPPORT ASSEMBLE 2 x 4 x 43 1 2 x2 2311 MS SWING BEAM SUPPORT 10 Hex Bolt Flat Washer Lock Nut 4 Hex Bolt 4 Hex Bolt Flat Washer Lock Nut Acorn Nut Flat Washer Flat Washer Flat Washer T Nut INSTAL...

Page 37: ...35 INSTALL SWING BEAM ASSEMBLY TWO PEOPLE AND A STEP LADDER ARE RECOMMENDED FOR THIS STEP USE CARE WHEN INSTALLING SWING BEAM ASSEMBLY SWING SIDE...

Page 38: ...swing beam assembly in place while marking holes INSTALL STEP 1 SWING SIDE Flush SAME MEASUREMENT SAME MEASUREMENT SWING BEAM ASSEMBLY INSTALL STEP 2 Drill 9 16 holes through at marked locations Conf...

Page 39: ...and align parts 1026 MS parallel on ground Hint Number the order of each part 1026 MS for correct re orientation top to bottom Mark parts on back side or use masking tape Lay Out the Climbing Rocks x1...

Page 40: ...Rock Wall Deck Boards using the marked hole locations LAY OUT PARTS ROCK LOCATIONS ROCK WALL ROCK WALL INSTALL T NUTS Turn all eleven 1026 MS panels over lay on a soft but firm surface Pound in 1 4 T...

Page 41: ...ion Align Climbing Rocks back into position over their holes 1 4 x 1 1 2 Hex Head Bolts 1 4 Lock Washers T Nuts 1 4 Flat Washers ROCK WALL LAY OUT PARTS ROCK LOCATIONS ROCK WALL INSTALL 2 1 2 Screws x...

Page 42: ...eat this step four more times with remaining Ladder Rungs 21 1 2 Approximately 13 1 2 between each Ladder Rung 1025 MS Step 1 Step 2 Feed Ropes through front of Rope Lad der Bottom Support 1088 MS Tie...

Page 43: ...at it can not be looped back on itself Feed lower end of Climbing Rope through hole in Lower Rail 1088 MS and tie a double knot on the back side Fig 1 Keep tying double knots at the bottom end of rope...

Page 44: ...ood Screw T Nut x4 Lock Washer x4 Flat Washer x4 3 1 2 Hex Bolt x4 Flush at peak STEP 1 STEP 2 T Nuts are facing inward Lay out four rafter halves 1198 MS as shown Pound in T Nuts Flush at peak 2 x 4...

Page 45: ...panels on rafters Ensure equal overhang on both sides about 7 8 43 3 8 Maintain 43 3 8 dimension between rafters 7 8 7 8 2 1 2 Wood Screws x 16 Insert panels fully seated INSTALL FOUR 4 PANELS 5 4 x...

Page 46: ...Wood Screws x 10 1 x 3 x 58 1 2 1204 MS x1 1 x 3 x 58 1 2 1204 MS x1 Flush Flush INSTALL FOUR 4 PANELS WARNING Install screws flush with roof board to avoid protruding below roof WARNING Install screw...

Page 47: ...nside Screws installed from outside 5 8 x 3 1 4 x 32 1 2 x2 1201 MS 3 8 x 6 x 16 x2 1202 MS ROOF ROOF BOARDS 2 1 2 Wood Screws x 56 5 4 x 6 x 47 3 4 1203 MS x14 1 1 4 Wood Screws x 28 INSTALL FOURTEEN...

Page 48: ...in Then using the Spring Clips attach the Swings to the swing brackets on the swing beam as shown below Attach Playset Plaque using One 1 Philips Head Screw provided at each corner of Plaque x6 8 Mini...

Page 49: ...threads are exposed INSTALL I M P O R T A N T Two people may be required to install and tighten Lock Nuts 2011 TIRE SWING SUPPORT BUTTON HEAD BOLTS 9 16 Drill through parts 1085 MS and 1033 MS 2 3 4...

Page 50: ...dd Acorn Nut and tighten against Lock Nut 8 Eye Bolt x3 Tighten Lock Nut until three 3 threads are exposed Use a screwdriver to hold Eye Bolt in place when tightening Lock Nut and Acorn Nut Fender Was...

Page 51: ...Quick Clip x3 8 minimum between Tire and ground Adjust Chains at Top Use a wrench to tighten Quick Clips securely closed Hold Quick Clip with pliers or screwdriver while tightening I M P O R T A N T...

Page 52: ...are resting flat on the ground It may be necessary to loosen the soil beneath Playset to make everything level 2 1 2 Wood Screws x4 2 1 2 Wood Screws x4 2 1 2 Wood Screws x4 Stakes Flush with TOP Sta...

Page 53: ...Wood Screw x2 1 3 4 Position Slide Mount beneath Deck End Board Attach with two 1 5 8 Wood Screws as shown Part 1051 MS is flush with 1011 MS Fort Floor Support Flush 2 x 4 x 15 3 8 1051 MS 2 x 4 x 1...

Page 54: ...E Slide DRILL Slide Slide 3 3 4 Flush Drill 1 8 holes at both dimples through Slide and 2312 MS into 1051 MS 1 inch deep 2015 5 4 x 6 x 41 1 2 2312 MS 1 x 6 x 41 1 2 2312 MS 5 4 x 6 x 47 3 4 1085 MS 2...

Page 55: ...53 SLIDE MOUNTING SCREWS 2 1 2 Pan Head Wood Screw x2 1 4 x 1 Fender Washer x2 SLIDE SURFACING MATERIAL Apply Surfacing Material at recommended depth or deeper 5 4 x 6 x 41 1 2 2312 MS...

Page 56: ...tach Left and Right Safety Handles to the Step Ladder Rails with two 1 4 x 1 1 2 Lag Bolts through 1 4 Flat Washers Attach third Safety Handle as shown The height of the handles is to be determined by...

Page 57: ...O NOT OVER TIGHTEN LAG BOLTS INSTALL ROPE LADDER BOTTOM SUPPORT GUSSETS 3 1 2 Lag Bolt Lock Washer Flat Washer Lock Washer 4 Lag Bolt Flat Washer DO NOT OVER TIGHTEN LAG BOLTS DO NOT OVER TIGHTEN LAG...

Page 58: ...56 TELESCOPE INSTALL Telescope Telescope Bracket Any Top Rail 1 1 4 Screws 2073 IF YOU HAVE MONKEY BARS PROCEED TO NEXT PAGE YOU HAVE FINISHED YOUR BASE PLAYSET STOP...

Page 59: ...LADDER SUPPORTS INSTALL 5 Hex Bolt 8 1 4 Flat Washer T Nut T Nut T Nut 5 Hex Bolt x2 Flat Washer 3 1 2 Hex Bolt Flat Washer Lock Washer x2 2 x 4 x 43 1 2 2322 MS x2 2 x 4 x 43 1 2 2322 MS NOTE Part 23...

Page 60: ...ASSEMBLY LEFT SIDE TWO PEOPLE AND A STEP LADDER ARE RECOMMENDED FOR THIS STEP INSTALL POSITION INSTALL STEP 1 LEFT SIDE Hint Clamp Monkey Bar Assembly in place while marking holes 4 1 2 Flush at bott...

Page 61: ...l Through 1 4 marked locations Re Drill through using 1 2 bit from outside of frame at each support hole location SEE PAGE 8 SEE PAGE 8 Flush at bottom 4 1 2 FROM INSIDE OF 3x3 CORNER POST Flat Washer...

Page 62: ...2324 MS as a 3 1 4 spacer 3 Install each 2324 MS flush at bottom INSTALL THIS BALUSTER FIRST INSTALL THIS BALUSTER FIRST CENTER Flush Locate middle spacer centered between Monkey Bar vertical supports...

Page 63: ...embly instructions Plastic end caps and hole plugs have been properly installed on plastic coated wood 2 The unit has been regularly and properly maintained and inspected 3 The failure occurs when the...

Page 64: ...implied warranty lasts so the above limitation may or may not apply to you Backyard Play Systems does not assume or authorize any person to assume for us any other liability in connection with the sal...

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