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SportsPlay Zack 911-131, Manual

The SportsPlay Zack 911-131 user manual is an essential companion for enthusiasts of this remarkable product. Packed with detailed instructions, troubleshooting tips, and valuable insights, this manual ensures that you make the most of your experience. Download it for free at manualshive.com and unlock the potential of your SportsPlay Zack 911-131.

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Page 2 

INDEX 

 
 
INDEX ...................................................................................... 2 
Tool and Material Checklist...................................................... 3 
Introduction............................................................................... 4 
Quick Guide .............................................................................. 5 
Safety Surfacing/Fall Heights ................................................... 7 
Punch List ................................................................................. 9 
Top Down View Scale ............................................................ 11 
Footing Diagram ..................................................................... 12 
Post Installation....................................................................... 13 
Deck and Pipe Clamp Installation........................................... 15 

Deck Clamp 

903-002 ................................................... 15 

Pipe Clamp 

903-001 ....................................................... 15 

Deck Clamp Plan: ............................................................... 16 
Pipe Clamp Plan:................................................................. 17 

Deck Installation ..................................................................... 19 

Square Deck ........................................................................ 19 
Triangle Deck...................................................................... 19 
Deck Plan:........................................................................... 20 

Kickplate ................................................................................. 21 

Kick Plate Plan:................................................................... 22 

Transfer Station 

 902-258 .................................................. 23 

Transfer Station Plan: ......................................................... 25 

Bubble Panel 

    902-117 ................................................... 27 

Bubble Panel Plan:.............................................................. 28 

Store Panel 

 902-206 .......................................................... 29 

Store Panel Plan: ................................................................. 30 

Guard Wall 

 902-135-W ..................................................... 32 

Guard Wall Plan:................................................................. 33 

“U” Climber 

 902-129-3, -4, -5, -6................................... 34 

“U” Climber Plan:............................................................... 35 

Tic Tac Toe Panel     902-121............................................... 36 

Tic Tac Toe Panel Plan:...................................................... 37 

Guard Wall 

 902-135-W ..................................................... 38 

Guard Wall Plan:................................................................. 39 

Steering Wheel 

 902-114 .................................................. 40 

Steering Wheel Plan:........................................................... 41 

Double Wall Straight Slide   902-213, 4, 5........................... 42 

Double Wall Straight Slide Plan:........................................ 43 

Label Installation .................................................................... 44 

Top of Surfacing Label ....................................................... 44 
Warning Label .................................................................... 44 
Manufacturer Label............................................................. 44 

Trouble Shooting .................................................................... 45 
Safety Checklist ...................................................................... 46 
Photo Appendix ...................................................................... 47 

 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for Zack 911-131

Page 1: ...Page 1 800 727 8180 www sportsplayinc com 911 131 Model Zack ...

Page 2: ...22 Transfer Station 902 258 23 Transfer Station Plan 25 Bubble Panel 902 117 27 Bubble Panel Plan 28 Store Panel 902 206 29 Store Panel Plan 30 Guard Wall 902 135 W 32 Guard Wall Plan 33 U Climber 902 129 3 4 5 6 34 U Climber Plan 35 Tic Tac Toe Panel 902 121 36 Tic Tac Toe Panel Plan 37 Guard Wall 902 135 W 38 Guard Wall Plan 39 Steering Wheel 902 114 40 Steering Wheel Plan 41 Double Wall Straigh...

Page 3: ...ocket style small L arm wrench styles etc Vise grips large regular and needle nose 3 4 and 1 2 and 9 16 sockets both 1 2 and 3 8 drives 6 and 8 stepladders strong ones Extension cords also duplexes to run more than one cord 1 2 drill and 3 8 drill 1 2 and 1 2 drill bits and 1 2 spade bits Levels magnetic torpedo 4 long etc as many as possible Shims and blocks from scrap lumber and a saw to cut siz...

Page 4: ...e equipment at regular intervals During inspection if any part is found damaged or excessively worn equipment should immediately be put out of service while the part is replaced Lack of maintenance will result in premature wear reduced life expectancy and possible failure that might result in injury All SportsPlay Equipment play events have been engineered to meet all applicable safety guidelines ...

Page 5: ...UPPLIES Set your installation date and order supplies from your local building center You will need some flat concrete stones for blocking holes some scrap lumber for bracing and cement You can figure about 2 80 bags per hole DECK LAYOUT Find the grid drawing in the instruction booklet Decide which way to orient the structure ALL fall zone measurements MUST be accommodated Locate the lowest deck o...

Page 6: ... decide how much safety surfacing is required Before spreading loose fill surfacing be sure to install a weed barrier outside the fall zone dimension then spread the safety surfacing LAST THING Make one more tour around the playground and physically make sure all hardware is tight OPEN FOR PLAY After the safety surfacing is installed and the hardware has been checked for tightness your playground ...

Page 7: ...member that loose fill will compress with repeated use Weed mat Some use a landscaping fabric material that allows drainage but prevents weed growth Weed mats are installed after the structure is installed but before the resilient surfacing is installed Borders Building borders above ground below grade or on grade depends upon the area in which you live Assuming you must use 12 of resilient surfac...

Page 8: ...djust your dirt grade height accordingly Chart taken from The Handbook for Public Playground Safety written by the U S Consumer Product Safety Commission CPSC page 5 www cpsc gov Material Uncompressed Depths Compressed Depths 6 9 12 9 Wood Chips 4 10 11 10 Double Shredded Bark Mulch 6 10 11 7 Engineered Wood Fibers 6 7 12 6 Fine Sand 5 5 9 5 Course Sand 5 5 6 4 Fine Gravel 6 7 10 6 Medium Gravel 5...

Page 9: ...k and mark a line on the other three posts at the same distance Now use a four foot level across to each line raising or lowering as necessary to make the lines level Repeat this for the remaining two posts Step 3 Deck and Post Installation 1 Measure 36 plus the amount of safety surfacing you are planning on using example 36 12 48 from the existing ground level Make a mark on the first post at thi...

Page 10: ... Do not dry bag the concrete always mix per instructions on concrete bag Be sure to leave concrete about 2 from the top of the ground to allow backfill 2 Be sure that all splattered concrete is washed off of the posts and components while it is still wet 3 Block off installation area for at least 48 hours Step 6 Final after 48 hours 1 Return in 2 days to backfill concrete drill and install drive r...

Page 11: ...sportsplayinc com Sheet 1 of 1 Scale 1 96 5642 Natural Bridge SportsPlay Date Drawn By SportsPlay SportsPlay SportsPlay SportsPlay 5 4 3 2 1 Candy 05 24 05 Zack 911 131 ASTM Compliant CPSC Compliant 800 727 8180 Fax 314 389 9034 Age Appropriateness 5 12 Yrs Size 22 x 14 5 Use Zone 34 x 26 5 Critical Fall Height 72 ...

Page 12: ...mpliant CPSC Compliant 800 727 8180 Fax 314 389 9034 Age Appropriateness 5 12 Yrs Size 22 x 14 5 Use Zone 34 x 26 5 Critical Fall Height 72 SLIDE 902 213 DOUBLE WALL PYRAMID 902 258 STATION TRANSFER ROOF 902 206 BELOW STORE PANEL 902 117 ABOVE SPIRAL BUBBLE PANEL 902 275 902 282 SLIDE 902 135 WALL 902 114 902 135W PANEL 902 121 TIC TAC TOE W WHEEL 902 129 4 36 U GUARD WALL GUARD 44 CLIMBER DASHED ...

Page 13: ...ing the deck on ground and using it as jig Place 4 deck clamps one per corner spray paint through middle of clamp onto ground This marks where the centers of the postholes should be Remove the deck and clamps from the area Dig the 4 holes 22 deep and 12 wide Holes are straight down and flat bottomed Install 10 diameter plywood in hole bottoms and place a brick in the bottom of the hole Use a marke...

Page 14: ...Page 14 Side view of installed post ...

Page 15: ...Roll Pin 1 4 x 1 3 4 1 5 236 601 3 8 T Nut 1 6 196 555 Roll Pin 1 4 x 3 4 1 7 126 703 3 8 x 1 Button Head Bolt 1 8 226 801 1 2 Lock Nut 1 9 316 801 1 2 Washer 2 Pipe Clamp 903 001 Item Part Part Description Quantity 1 904 002 Clamp half BACK 1 2 904 001 Clamp half FRONT 1 3 126 706 3 8 x 1 3 4 Button Head Bolt 2 4 196 807 Socket Set Screw 3 8 x 3 8 1 5 236 601 T Nut 3 8 2 6 196 555 Roll Pin 1 4 x ...

Page 16: ...the clamp onto the post 7 Install Roll Pins When the playground has been built and there are no more adjustments drill through all of the clamps through pre drilled 1 4 drill holes in clamps and the 5 O D posts Use a sharp 1 4 metal drill bit to drill a straight hole Do not egg out the holes Then tap a 3 4 roll pin through clamp into post so that the pin is flush with the clamp Do not allow pins t...

Page 17: ...pe with a rubber hammer If that will not work take clamp off and install it sideways placing it on the pipe first and then onto the post Pipes enter into clamps 2 1 4 deep Components like walls vertical climbers ladder ends etc are all 48 long and the pipe ends have to go straight into the clamps or the connection will not work If you force a clamp it can break All of our components such as walls ...

Page 18: ...ONS Event Clamps shall be 606ITS aluminum fastener for 5 OD posts weighing 2 21 lbs Paint shall be elecrtostatically applied oven cured powdercoat Hardware Stainless Steel tamper resistant MAINTENANCE Touch up any marred paint surfaces Periodically check hardware for integrity and tightness ...

Page 19: ... 002 Deck Clamp Assembly 4 4 316 801 1 2 Washer 8 5 226 801 1 2 Lock Nut 4 6 126 703 3 8 x 1 Button Head Bolt 4 Triangle Deck Item Part Part Description Quantity 2 903 002 Deck Clamp Assembly 3 3 905 710 Triangle Deck 1 4 316 801 1 2 Washer 6 5 226 801 1 2 Lock Nut 3 6 126 703 3 8 x 1 Button Head Bolt 3 ...

Page 20: ...ll the 4 deck clamps so that there is 42 1 4 between the holes in the deck clamps Use a level and a marker to make sure the clamps are level to each other Place deck onto clamps and bolt This method works but is less stable than the first method The deck and posts will stabilize more as you add components Pre install deck clamps and level SPECIFICATIONS Event Steel Deck shall be constructed of 12 ...

Page 21: ...te Item Part Part Description Quantity 1 902 246 902 247 902 249 9 x 37 Kick plate 12 x 37 Kick plate 26 x 37 Kick plate 1 2 316 601 3 8 Flat Washer 16 3 126 701 3 8 x 1 1 4 Button head bolt 8 4 226 601 3 8 Lock Nut 8 ...

Page 22: ...he higher deck and the BACK of the lower deck Bolt kick plate to both decks Insure that all hardware is tight SPECIFICATIONS Event Kick plates are powdercoated Paint shall be electrostatically applied oven cured powdercoat Hardware Stainless steel tamper resistant MAINTENANCE Touch up any marred paint surfaces Periodically check hardware for integrity and tightness ...

Page 23: ... 7 903 001 Pipe clamp 2 8 913 227 Hand rail left 1 9 913 228 Hand rail right 1 10 913 230 Inside leg 2 11 105 016 1 7 8 aluminum pipe plug 2 12 126 701 3 8 x 1 1 4 button head bolt 14 13 126 704 3 8 x 3 button head bolt 2 14 126 707 3 8 x 1 1 2 button head bolt 4 15 126 708 3 8 x 2 1 4 button head bolt 4 16 217 104 3 8 rebar 4 17 226 602 3 8 Nylon lock nut 24 18 316 601 3 8 Flat washer 44 19 385 9...

Page 24: ...Page 24 ...

Page 25: ...ked up vertically and horizontally on bubble 11 Determine on which side the step plank will be located by viewing the Top Down drawing 12 The handhold post will connect to the front step to the opposite side of the step plank 13 Connect the transfer deck bottom front with 1 3 8 by 3 button head bolt washer both sides and lock nut under the transfer deck 14 Connect the short post 44 long to the oth...

Page 26: ...ect with 2 3 8 by 1 1 4 button bolts no washer on the outside and 2 3 8 washer and lock nuts on underside of deck Re check levels of all 6 posts and the bottom plank and the entire transfer step Make sure it is all level and blocked SPECIFICATIONS Event Transfer Station shall be constructed of 9 gage by 3 4 flattened expanded metal including offset kickplates to fully enclose gaps between decks an...

Page 27: ...ntity 1 435 665 Bubble panel 1 2 903 001 Pipe Clamp 4 3 903 309 Spacer Bar preinstalled 2 4 903 103 Panel Support preinstalled 2 5 196 807 3 8 x 3 8 Socket Set Screw 8 6 196 555 1 4 x 3 4 Roll Pin 4 7 236 901 3 8 T Nut 8 8 126 706 3 8 x 1 3 4 Button head bolt 8 ...

Page 28: ...el and the nearest edge of the deck Installation above or below deck requires the same distance between the wall and deck This measurement is CRITICAL for the safety of the users Install the panel to the clamps See Detail A and C Center the panel between the posts The bubble faces OUT or away from the deck To center adjust the vertical spacer bars between the posts and panel by adjusting the set s...

Page 29: ...l Bracket 2 3 903 001 Pipe Clamp 4 4 316 501 5 16 Flat Washer 6 5 116 529 5 16 x 3 4 Button Head Bolt 6 6 216 512 5 16 x 1 Button Head Nut 6 7 126 706 3 8 x 1 3 4 Button Head Bolt 8 8 196 555 1 4 x 3 4 Roll Pin 4 9 196 807 3 8 x 3 8 Socket Set Screw 4 10 316 601 3 8 Flat Washer 6 11 236 601 3 8 T Nut 8 ...

Page 30: ... pipe fitting into the pipe clamp Once set repeat for the other side Install with no more than 3 1 2 between the wall and the nearest edge of the deck Installation above or below deck requires the same distance between the wall and deck This measurement is CRITICAL for the safety of the users It is helpful to install with a couple of equal size shims under the wall to help hold the wall in positio...

Page 31: ...Page 31 ...

Page 32: ...35 W Item Part Part Description Quantity 1 913 117 W Guard Wall fitting 1 2 903 001 Clamps 4 3 196 807 3 8 x 3 8 Socket Set Screw 4 4 196 550 1 4 x 3 4 Roll Pin 4 5 236 601 3 8 T Nut 8 6 126 706 3 8 x 1 3 4 Button Head Bolt 8 ...

Page 33: ...he top of the deck It is helpful to install with a couple of equal size shims under the wall to help hold the wall in position Review the clamp instructions for sideways attachment of clamps SPECIFICATIONS Event the 10 Rung Guard Wall is 48 wide and acts as a barrier to prevent falls from decks Horizontal pipes that fit into post clamps are 1 3 8 OD Vertical pipes are 1 OD Paint shall be electrost...

Page 34: ... U Climber 3 deck U Climber 4 deck U Climber 5 deck U Climber 6 deck 1 3 903 001 Pipe Clamp 4 4 196 555 1 4 x 3 4 Roll Pin 4 5 196 807 3 8 x 3 8 Socket Set Screw 4 6 236 601 3 8 T Nut 8 7 126 706 3 8 x 1 3 4 Button head bolt 8 8 116 535 5 16 x 1 1 2 Button head bolt 1 9 326 501 5 16 Lock Washer 1 10 216 512 5 16 x 1 Button head nut 1 ...

Page 35: ...arch entry opening Make sure all gaps between walls and posts and deck are less than 3 1 2 Install U Climber 19 out from the deck SPECIFICATIONS Event U Climber is constructed of 16 diameter half circles welded to vertical 1 7 8 L pipe all are 1 3 8 outer diameter Metal brackets are powdercoated Paint shall be electrostatically applied oven cured powdercoat Hardware Stainless steel tamper resistan...

Page 36: ...02 121 Item Part Part Description Quantity 1 903 121 Tic Tac Toe Panel 1 2 903 001 Post Clamp 4 3 196 807 3 8 x 3 8 Socket Set Screw 4 4 196 555 1 4 x 3 4 Roll Pin 4 5 236 601 3 8 T Nut 8 6 126 706 3 8 x 1 3 4 Button head bolt 8 ...

Page 37: ...nstall with a couple of equal size shims under the wall to help hold the wall in position When the unit is installed on bubble equally space the spacer bars on each side between the posts using the allen wrench SPECIFICATIONS Event Tic Tac Toe Panel shall be constructed of cylindrical blocks with silkscreen letters are held by 7 8 OD pipe Event is 48 wide and attaches with four pipe clamps Paint s...

Page 38: ...35 W Item Part Part Description Quantity 1 913 117 W Guard Wall fitting 1 2 903 001 Clamps 4 3 196 807 3 8 x 3 8 Socket Set Screw 4 4 196 550 1 4 x 3 4 Roll Pin 4 5 236 601 3 8 T Nut 8 6 126 706 3 8 x 1 3 4 Button Head Bolt 8 ...

Page 39: ...he top of the deck It is helpful to install with a couple of equal size shims under the wall to help hold the wall in position Review the clamp instructions for sideways attachment of clamps SPECIFICATIONS Event the 10 Rung Guard Wall is 48 wide and acts as a barrier to prevent falls from decks Horizontal pipes that fit into post clamps are 1 3 8 OD Vertical pipes are 1 OD Paint shall be electrost...

Page 40: ...tem Part Part Description Quantity 1 Welded wheel fitting 2 905 117 Steering Wheel 1 3 902 135 W Guard Wall with welded wheel fitting 1 4 116 600 1 2 x 1 2 Button Head Bolt 1 5 316 801 1 2 Flat Washer 5 6 226 802 1 2 Nylon Lock Nut 1 ...

Page 41: ... wheel and plate Place one washer inside the wheel under the lock nut Tighten the nut The wheel should be tight but yet still able to turn Snap on the cover over the bolt assembly SPECIFICATIONS Event Steering Wheel shall be constructed of a polycarbonate 12 diameter wheel countersunk wheel hub connects to wall with non slip double plate center 1 2 bolt and lock nut Hardware Stainless steel tamper...

Page 42: ...Guard 1 3 903 214 Slide Leg 2 4 903 001 Pipe Clamp 4 5 903 213 Z Plate installed on slide 1 6 126 701 3 8 X 1 1 4 Button head bolt 2 7 316 601 3 8 Flat Washer 11 8 226 602 3 8 Lock Nut 2 9 196 555 1 4 x 3 4 Roll Pin 4 10 196 807 3 8 x 3 8 Socket Set Screw 4 11 126 706 3 8 x 1 3 4 Button head bolt 8 12 236 601 3 8 T Nut 8 13 126 702 3 8 x 3 4 Button head bolt 7 Deck Height Post Footing Distance 36 ...

Page 43: ...de with installed legs and re bars through the hole in the bottom of the slide legs into the ground Carefully tip the top of the slide back onto the deck Make sure you ream the vinyl coated holes out 15 apart with a 1 2 metal bit Connect the Z plate to the deck with two 3 8 x 1 1 4 button head bolts no washer on top and 3 8 washer and lock nut on the bottom Place a level over the bottom to be sure...

Page 44: ...or faded contact your SportsPlay distributor for replacement labels Top of Surfacing Label Install one to each upright post at the level you have determined will be your Top of Surfacing based on fall height and resilient surfacing used Warning Label Install two labels at eye level to different upright posts at locations most likely to be used to access the play unit Manufacturer Label Install lab...

Page 45: ... installed and you have to move it Solution Using a punch simply knock the roll pin through the clamp and post then move the clamp Problem There is interference between a vertical portion of one component and another vertical portion of another component going into the opposite direction For instance in the case of a tunnel or bubble window that has a vertical spacer bar Solution Loosen the spacer...

Page 46: ... ends sometimes rough handling will cause rough edges Sand down rough areas if they exist Check that screws are seated Vinyl coated parts check all areas to de burr Roll pins make sure they are flush and to not stick out Clamps when aluminum is hammered it can cause a rough area De burr if necessary Bolt thread protrusions two threads are maximum protrusion allowed If more than two threads are vis...

Page 47: ...e instructions Photographs have been included for those who prefer them 1 Mark post hole positions 2 Install post 3 Install deck 4 Install deck clamp 5 Install pipe clamp 6 Install panel slide guard arch wall etc to pipe clamp 7 Leveling Suggestion 8 Leveling Suggestion ...

Page 48: ...Page 48 1 2 4 3 ...

Page 49: ...Page 49 5 6 8 7 ...

Page 50: ...air and could be hazardous Copy this page and explain R ratings on reverse side Equipment 36 deck Transfer station Crawl tunnel Alpha panel Guard wall with wheel Triple rail slide Slide guard Deck clamps Post clamps Large handhold Small handhold Resilient Surfacing Depth Broken glass trash foreign objects etc Exposed or loose concrete footings other trip hazards Missing or broken parts Sharp or ja...

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