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Rainbow Play Systems Carnival Castle, Assembly Instructions Manual, Page: 25 / 59

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Rainbow Play Systems Carnival Castle Assembly Instructions Manual Download Page 25

A

B

COUNTER-SUNK

HOLES

CARPENTER'S

SQUARE

ROCK WALL

LADDER

ASSEMBLY

STEP/RUNG

LADDER

ASSEMBLY

277

268

272

273

302

DETAIL A

NO GAPS

H108

H1

H34

266

272

H3

H117

H3

H11

H132

H1

H108

302

268

H28

DETAIL B

FACES

FLUSH

302

277

266

     

*NOTE:  This step requires two or more people to complete.  

     *NOTE:  For ease of assembly, have all required parts and hardware in close proximity.  

     *NOTE:  Pre-drill holes for all Lag Bolts with the appropriate drill bit.

     *NOTE:  Do not fully tighten hardware at this time. 

     

*NOTE:  3/8" Hardware (H28) is shown but will not be installed until Step 8.

1.  Pick up on the Step/Rung Ladder assembly so the outside faces of the Ladder Legs 

(268) (277)

 are 

     flush with the angled faces of Angled Facias 

(302)

 and Main Beams 

(266)

 (as shown 

     in DETAIL B).

2.  Position Corner Uprights 

(272)

 between Main Beams and Angled Facias with counter-sunk holes 

     facing one another, and attach to Facias and Main Beams using 3/8" Hardware 

(H3) (H11) (H34) 

     (H132)

 (as shown in DETAIL A).

      

*NOTE:  Use a carpenter's square to ensure Corner Uprights (272) are square with Facias and 

                     Main Beams.

3.  Finish securing the Ladder assembly by attaching Ladder Legs 

(268) (277)

 to Facias, Main Beams, 

     and Corner Uprights using 1/4" Hardware 

(H1)

, 5/16" Hardware 

(H108)

, and 3/8" Hardware 

(H3) 

     (H117)

 (as shown in DETAIL A).  Gaps between Corner Uprights 

(272)

 and Ladders Legs should be 

     minimal.

4.  Repeat parts 1 through 3 for the Rock Wall Ladder assembly.

24

Step 6

Main Beam, Facia, and

Ladder Assembly

Summary of Contents for Carnival Castle

Page 1: ...ions Be sure to educate all children who use this playground and all adult supervisors about the rules for safe use that are contained in this manual Keep this Owner s Manual for future reference and...

Page 2: ...s to help with building your playground WARNING Failure to follow the assembly location use and maintenance instructions in this manual could result in serious injury to children using this playground...

Page 3: ...l ages 3 WARN CHILDREN TO AVOID playing or walking in front of behind or between moving equipment 4 WARN CHILDREN NOT TO twist swing chains or ropes or to loop them over the top support bar since this...

Page 4: ...shington D C 20207 Playground equipment should never be placed on hard surfaces such as concrete or asphalt Do not use loose fill surfacing on top of hard surfaces such as concrete or asphalt While gr...

Page 5: ...inches Tighten close as necessary 7 Remove plastic swing seats and take indoors or do not use when temperature drops below 32 Fahrenheit Reinstall swing seats when the cold season is complete 8 Check...

Page 6: ...you do not lose any hardware 8 Before starting each Step thoroughly read all of the instructions to ensure all information is understood Pay special attention to the orientation of each part details...

Page 7: ...ipment A check is a separation of the wood fibers running with the grain This is caused by varying temperature and moisture conditions By coating your Play System annually with a sealant or preservati...

Page 8: ...IC TAC TOE BOARD 3 04 0010 1 2 x 4 x 45 TARP BOARD 3 03 0040 2 2 x 6 x 79 11 16 MAIN BEAM 3 04 0009 2 4 x 4 x 104 A FRAME LEG 3 06 0003 1 4 x 4 x 60 A FRAME CROSS MEMBER 3 06 0004 1 4 x 4 x 15 UPPER A...

Page 9: ...4 x 45 ROCK WALL BOARD w ROPE HOLE 3 09 0014 9 5 4 x 4 x 44 7 8 DECK BOARD 3 09 0016 8 5 4 x 4 x 45 2 HOLE INSIDE ROCK WALL BOARD 3 09 0013 4 5 4 x 4 x 39 SHORT DECK BOARD 3 09 0015 1 5 4 x 4 x 72 DE...

Page 10: ...3 01 0069 4 1 x 4 x 6 1 2 CHIMNEY TRIM 3 01 0092 1 1 x 4 x 13 FAN VERTICAL 3 01 0099 1 1 x 4 x 13 9 16 LEFT DORMER BOARD 3 01 0101 1 1 x 4 x 9 1 2 LEFT DORMER BOARD 3 01 0103 1 1 x 4 x 5 7 16 LEFT DO...

Page 11: ...2 x 4 x 24 1 4 LEFT DORMER SUPPORT 3 03 0052 2 5 4 x 4 x 66 1 2 ROOF RUNNER 3 09 0025 6 5 4 x 4 x 17 1 2 WINDOW TRIM 3 09 0026 2 5 4 x 4 x 17 1 2 ARCHED WINDOW TRIM 3 09 0027 1 5 4 x 4 x 41 1 4 WINDO...

Page 12: ...1 45 BRACKET 5 35 0094 4 LONG CHAIN 5 37 0027 5 SHORT CHAIN 5 37 0026 3 CASTLE LADDER HANDLE 5 33 0103 1 TRAPEZE BAR 5 40 0063 4 PEAR QUICK LINK 5 47 0045 4 C LINK 5 47 0044 9 SPRING CLIP 5 47 0023 2...

Page 13: ...IDE 5 44 0139 3 14 ROPE 5 20 0279 1 12 ROPE 5 20 0124 1 CHALKBOARD w CHALK AND ERASER 5 20 0134 1 4 Chain Tire Swing 1 Half Bucket Swing designed for children ages 3 5 N41 N24 N2 N1 N167 N169 N17 Carn...

Page 14: ...6 Lag Bolt 3 8 x 3 1 2 6 H117 Lag Bolt 3 8 x 4 8 H119 Lag Bolt 3 8 x 5 5 H126 Hex Bolt 3 8 x 2 2 H129 Hex Bolt 3 8 x 3 1 2 3 H132 Hex Bolt 3 8 x 5 8 H135 Hex Bolt 3 8 x 6 1 2 12 H139 Hex Bolt 3 8 x 9...

Page 15: ...0 1 2 3 4 5 6 7 8 9 H191 H152 H158 H167 H164 H14 H12 H5 H7 H1 H3 H4 H9 H11 H17 H28 H24 H32 H34 H30 H18 H29 H194 H154 H155 H157 H188 14 Hardware for Assembly...

Page 16: ...0 1 2 3 4 5 6 7 8 9 H60 H128 H56 H126 H50 H129 H130 H55 H135 H132 Hardware for Assembly NOTE Thread length may vary from what is pictured 15...

Page 17: ...cket 9 16 Deep Well Socket 9 16 Box Wrench 8 Step Ladder Safety Glasses Adult Helper 36 Bar Clamp optional Electric Impact Gun or 1 4 and 3 8 Ratchet 1 8 Drill Bit 1 4 Drill Bit 5 16 Drill Bit 9 16 Dr...

Page 18: ...77 78 77 82 81 N171 86 N29 N15 N31 N13 N246 N26 N14 N18 N30 N16 N12 N12 N6 274 269 268 276 277 293 N3 303 N41 302 291 354 N168 N172 279 N19 271 255 256 200 263 264 265 N5 257 PARTS IDENTIFICATION 17...

Page 19: ...N11 275 278 269 270 286 285 284 283 273 N5 N156 382 379 378 329 306 307 364 365 366 367 368 369 370 358 357 355 356 362 363 245 259 246 247 383 298 299 253 360 260 252 251 250 248 262 200 272 308 381...

Page 20: ...ung Ladder Leg 277 Pound the inside three Ladder Pipes N3 into the wood so they protrude approximately 19 1 2 from the wood and the outside two Ladder Pipes N3 approximately 20 1 2 from the wood NOTE...

Page 21: ...flush The final assembly width must be 45 2 Position the Lower Rope Runner 274 on the backside of the assembled ladder approximately 2 up from the bottom of the Ladder Legs as shown in Insets A and B...

Page 22: ...with the best surface down 1 Position Rock Wall Boards 284 285 on a flat surface and place 1 4 Hardware H32 into the pre drilled holes Use a hammer or rubber mallet to gently tap the hardware into pl...

Page 23: ...Step 5 NOTE The 8 Screws H152 used to attach Rockwall Runner are shorter than the 8 Screws H155 that are used for the Rock Wall Legs 3 Center Rock Wall Runner 294 under middle holes in Rock Wall Boar...

Page 24: ...Hardware should not be fully tightened at this time 1 On a flat surface position Main Beams 266 Angled Facias 302 and previously assembled ladders as shown and attach using 3 8 Hardware H3 H11 H34 H13...

Page 25: ...de faces of the Ladder Legs 268 277 are flush with the angled faces of Angled Facias 302 and Main Beams 266 as shown in DETAIL B 2 Position Corner Uprights 272 between Main Beams and Angled Facias wit...

Page 26: ...s step but will not be installed until Step 8 NOTE The counter sunk holes in Top Joists 278 and 279 must face down as shown in INSET A 1 Attach Top Joist with Monkey Bar Holes 278 and Top Joist with S...

Page 27: ...Lower Rope Runner Attach Upper Rope Arm 275 to Top Joists using 3 8 Hardware H3 H11 H17 H55 and 1 2 Hardware H4 3 Use a carpenter s square to verify that the Corner Uprights 272 Main Beams 266 Angled...

Page 28: ...s 287 304 288 305 to Main Beams 266 using 8 Hardware H152 3 Center Deck Runner 289 under middle holes in Deck Boards and attach Runner using 8 Hardware H152 4 Attach 120 Ladder Brackets N209 to Deck R...

Page 29: ...ttach Front Facia 292 and 2 Hole Facia 291 to Corner Uprights 272 using 1 4 Hardware H1 and 5 16 Hardware H108 NOTE Skip to Step 11 if installing the Wood Roof with Cabin Package 3 If installing the T...

Page 30: ...A NOTE Install two additional Rail Uprights 200 in place of Center Posts 263 if installing Wood Roof Option 1 Position Rail Uprights 200 255 257 258 and Bubble Rail Uprights 256 in the locations shown...

Page 31: ...wing Seat N15 and Half Bucket Swing N17 using Pear Links N31 and C Links N30 as shown in Inset A 3 Attach two Short Chains N12 to Trapeze Bar N18 using C Links N30 as shown in Inset A 4 Attach Trapeze...

Page 32: ...e orientated as shown using the 12 measurement 2 Open C Links N30 Divide the six Chains N12 into groups of three Chains Connect each group of Chains together using C Links N30 as shown in Inset A 3 At...

Page 33: ...e a box wrench or locking pliers to hold on to Hex Head Bolts H135 2 Position Plaque N83 in the approximate position shown and attach to Swing Beam using Hardware H157 or H158 3 Attach Swing Beam Plat...

Page 34: ...g Beam is lifted up into position SUGGESTION Use at least two people to lift Swing Beam assembly CAUTION Legs are very unstable until Cross Member 78 is installed 5 Tighten Hex Head Bolt H139 that goe...

Page 35: ...346 H108 H1 H164 78 H55 H4 H3 H11 H17 H28 77 77 H4 H55 H28 H17 H11 H3 H28 H100 H1 82 81 N26 346 279 H56 H4 N29 N170 N27 H3 H11 H17 H28 INSET A H4 H50 H4 H60 279 N10 346 Continued from previous page 34...

Page 36: ...s Drill through Deck Boards using a 9 16 drill bit Drill slowly to prevent drilling blowouts 2 Attach the Tire Swivel N25 though the Tire Swing Block 290 and the Deck Boards using 1 2 Hardware H4 H12...

Page 37: ...KNOTS MUST BE TIED IN ROPE AND ROPE MUST BE SECURE AT BOTH ENDS ROPE MUST BE TIGHT ENOUGH THAT IT CANNOT BE LOOPED BACK ON ITSELF AND NO MORE THAN 12 OF ROPE SHOULD BE LEFT AFTER TYING DOUBLE KNOTS A...

Page 38: ...linders N172 3 Place top Tic Tac Toe Board 385 on top of the last layer of Cylinders N172 Be sure that Rods N174 line up with the holes in the Tic Tac Toe Board 385 4 Center Tic Tac Toe Assembly in th...

Page 39: ...and attach using 8 Hardware H154 2 Remove protective covering from Bubble Window N168 and place Bubble Window on the back side of the assembled window frame The Bubble Window N168 should fit in the no...

Page 40: ...er Post make sure lag bolt goes through the Center Post and into the Top Joist 279 2 Attach Ship s Wheel to Center Post 263 or Swing Beam 346 using hardware found in Ship s Wheel bag Snap Cover N20 in...

Page 41: ...Ladder Legs using 14 Hardware H167 Castle Ladder Handles N6 should be approximately 18 up from the bottom face of the Ladder Legs 2 Attach Safety Handles N5 to Castle Ladder Legs in four locations sho...

Page 42: ...ble Wall Wave Slide N24 in the opening provided and attach to Deck Boards using 1 4 Hardware H7 and 14 Hardware H164 as shown in DETAIL A Wave Slide should sit approximately 4 to 5 back from the Angle...

Page 43: ...side of 2 Hole Facias 264 Starting with the middle tarp snaps gently tap each snap with a hammer to leave an indentation in the wood 3 Install Snap Screws H183 in the center of the indentations Snap S...

Page 44: ...protrude approximately 19 from the wood and the two outside Ladder Pipes N3 approximately 20 from the wood 3 Repeat part 2 for the Monkey Bar Support Leg 280 SUGGESTION Use a bar clamp to hold Monkey...

Page 45: ...2 Position the two inside Monkey Bar Plates N11 and insert 3 8 Hardware H30 into holes Use a hammer to gently tap hardware into holes if needed 3 Position the two outside Monkey Bar Plates N11 and at...

Page 46: ...ms 281 282 with pre drilled holes in Top Joist with Monkey Bar Holes 278 and attach using 3 8 Hardware H3 H11 H17 H28 H55 and 1 2 Hardware H4 NOTE Use an 1 8 drill bit to drill holes 1 2 deep for 14 H...

Page 47: ...the positions shown using 3 8 Hardware H3 H11 H34 H130 Do not fully tighten hardware at this time SUGGESTION Use a wood clamp or an adult helper to hold Roof Supports in position while Peak Facias are...

Page 48: ...bottom of the Roof Frame Top 306 on BOTH Roof Supports and attach Roof Frame Bottom 306 to Roof Supports using 8 Hardware H152 3 Position Roof Boards 245 on Roof Supports 360 361 between Roof Frame T...

Page 49: ...ame Sides 307 in locations shown and attach to Roof Boards 245 using 8 Hardware H152 When properly assembled outside faces of Roof Frame Top 306 and Roof Frame Sides 307 should be flush as shown in DE...

Page 50: ...Roof Boards 364 371 to Dormer Supports 357 358 using 8 Hardware H194 Do not leave gaps at the peak between the top two Dormer Boards For ease of assembly only put one screw in each Dormer Board until...

Page 51: ...ssembly should be centered horizontally and Dormer Supports 357 358 should be flush with the bottom edge of a Roof Board 245 2 Attach Dormer assembly to the roof through Roof Boards 245 and into Dorme...

Page 52: ...pieces on Chimney Sides 382 and attach using 8 Hardware H194 3 Center Chimney Trim 329 pieces on Chimney Back 379 and Chimney Front 378 and attach using 8 Hardware H194 4 Place Chimney Block 359 flus...

Page 53: ...er 383 approximately 17 3 4 on each side and the bottom of the Fan Center 383 should be 2 3 4 up from the bottom of the Fan Horizontal 259 as shown in INSET A and INSET B 2 Attach Fan Horizontal 259 a...

Page 54: ...248 262 as shown below and attach to Roof Supports 360 361 using 8 Hardware H194 Angled Faces of Cabin Horizontals should be flush 4 Position Window Trim Frame that was assembled in 1 against the outs...

Page 55: ...Angled faces of Cabin Horizontals should be flush 4 Position Window Frames that were assembled in 1 against the outside of the cabin in locations shown 5 Attach Notched Cabin Horizontal 260 and Cabin...

Page 56: ...p through the bottom of the Upper Rope Arm 275 and tie a double knot 2 Slide one Rope Rung 293 up on Ropes N2 with approximately 11 12 between the bottom of the Upper Rope Arm 275 and the top of the R...

Page 57: ...ng Beam Legs NOTE For maximum strength drive stakes into the ground at a slight angle WARNING ALL UNDERGROUND UTILITIES MUST BE LOCATED BEFORE ANCHORING PLAY SET 1 Drive Stakes N28 into the ground in...

Page 58: ...4 off of the outer end of Swing Beam 346 as shown 2 Router all sharp edges of cut end of Swing Beam 346 3 Stain cut end of Swing Beam with a non toxic water sealant intended for outdoor use NOTE When...

Page 59: ...ped freight prepaid For purposes of any warranty offered by Rainbow the following are not considered defects in materials and workmanship if they do not affect the functionality or structural integrit...

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