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Backyard Play Systems 4500 Assembly Manual

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Summary of Contents for Backyard Play Systems 4500

  • Page 1 2358...
  • Page 2 (This page intentionally left blank.)

  • Page 3: Before You Begin

    2358 05/27/2011 Customer Service Model 4500, Backyard Play Systems 1-866-890-2211 4505, 5005, 5008, 1000 Ternes Playset Monroe, MI 4816 6096, 6098. Recommended for Ages 3 to 11 - BEFORE YOU BEGIN - Tools Required Adult Assistance required First... Assistance is necessary to handle, ...
  • Page 4 (This page intentionally left blank.)
  • Page 5 ASSEMBLY SAFETY and HELPFUL HINTS ASSEMBLY SAFETY and HELPFUL HINTS STOP!!! Check all parts and hardware before beginning. If any parts are missing or damaged please circle and call the phone number listed. DO NOT CONTACT THE STORE OR RETURN YOUR PLAYSET ! KEEP THIS INSTALLATION MANUAL FOR FUTURE CARE AND MAINTENANCE REFERENCE.

  • Page 6: Safety Warnings

    SAFETY WARNINGS Please read carefully. Observing the following statements and warnings reduces the likelihood of serious or fatal injury.  This playset has been designed for use by a maximum of ten occupants at one time having a combined weight of 1,500 pounds. (This weight does not include occupants on the optional monkey bars, glider, or tire swing). ...

  • Page 7: Maintenance

    MAINTENANCE Periodic maintenance is required to ensure safe enjoyment of your playset and optional accessories. Observing the following procedures reduces the likelihood of serious or fatal injury.  Activity on your playset and optional accessories may loosen fasteners. Check all lock nuts, hex and lag bolts, quick clips, spring clips, acorn nuts, wood screws, and swing hangers for tightness and tighten as required.
  • Page 8 PLAYGROUND SURFACING MATERIALS SECTION 4 OF THE CONSUMER PRODUCT SAFETY COMMISSION’S OUTDOOR HOME PLAYGROUND SAFETY HANDBOOK Select Protective Surfacing One of the most important things you can do to reduce the likelihood of serious head injuries is to install shock-absorbing protective surfacing under and around your play equipment.

  • Page 9: Left Side

    PLAYSET 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: LEFT SIDE FRONT SIDE RIGHT SIDE...
  • Page 10 IMPORTANT! Use these Assembly Procedure Hints throughout the installation process. 1. All Lag Bolts must have pre-drilled holes. Use a 1/4” drill bit for all 3/8” Lag Bolts. Use a 3/16” drill bit for all 5/16” Lag Bolts. Pre-drilling pilot holes will help prevent Screws and Lag Bolts from breaking and wood from splitting during assembly.

  • Page 11: Base Parts List

    BASE PARTS LIST 5/8 x 3-1/4 x 32-1/2" 3/8 x 6 x 16" 1 x 3 x 58-1/2” WOOD 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” 1201-MS 1202-MS 1204-MS 5/4“...
  • Page 12 Swing Beam Flat Plate Swing Beam Flat Plate Swing Beam Angled Plate 2023 2098-H 2106-H Spring Clip Swing Hanger Plastic Hole-Plug Angled Angle plug 2003 2004 Climbing Rocks Plaque Sling Swing 2001 Yellow 2000 2035 2014 Green Rope Slide Safety Handle 2017-B 2015 2007...
  • Page 13 3/8” LAG BOLT WOODSCREWS x142 x49 x245 1-1/4” 1-5/8” 2-1/2” 3” 3” 3-1/2” 4” 1/4” SAFETY HANDLE HDW. 3/8” FLAT WASHER 1-1/2” x107 3/8” LOCK WASHER Flat Washer Screw #2 SQUARE DRIVE BIT 1/4” ROCK WALL HARDWARE 3/8” T - NUT Lock Washer Flat...
  • Page 14 A C T U A L S I Z E S H O W N 3-3/4” 4” 5-1/4” 3-1/2” 5-1/2” 3/8” 10” 3/8” 3/8” 3/8” 3/8” 3/8” 5-16 ” LAG BOLT 5/16” LOCK WASHER 3” 2-1/2” 5/16” 3” 5/16” FLAT WASHER 3/8”...

  • Page 15: Accessories Parts List

    ACCESSORIES PARTS LIST Telescope Steering Wheel 2073 2008-A Quick Clip Spring Clip 2020 2004 Tire Swing Hanger Chains 2011 2018 Tire 2120...
  • Page 16 ACCESSORIES HARDWARE LIST A C T U A L S I Z E S H O W N 3/8” ACORN NUT 1-1/4” 3/8” 3/8” 3/8” FLAT WASHER LOCK NUTS 3/8” 3/8” 3/8” FENDER WASHER 8” 3/8” x 2-3/4” 1-1/2” BUTTON HD. SCREW 3/8”...
  • Page 17 SET-UP ORIENTATION BACK SIDE 27’-1” 6’ SAFETY AREA SLIDE 15’-1” LEFT SIDE SWING SIDE 11’-1” HEIGHT 16’-3” 28’-3” SWING ROCK WALL 6’ SAFETY AREA FRONT SIDE SET-UP ORIENTATION BACK SIDE 32’-1” BASE PLAYSET WITH MONKEY BAR SAFETY AREA OPTION. SLIDE 20'-1"...

  • Page 18: Parts Layout

    FORT PARTS LAYOUT 3 x 3 x 44-1/8" 5/4 x 4-1/4 x 47-3/4" 5/4 x 6 x 47-3/4" *IMPORTANT! 2310-MS 1033-MS 1029-MS Lay Out Corner Posts 5/4 x 6 x 41-1/2" as shown 2312-MS LEFT SIDE Orient the 2-holes of 1033-MS “UP”. 1001-MS 2 x 4 x 75-1/2"...
  • Page 19 FORT CORNER POSTS / FLOOR Align two left-side and Decking Screws Pattern two right-side corner post 5/4 x 6 x 41-1/2" L x4 assemblies as shown. 2312-MS T-Nut x12 5/4 x 6 x 47-3/4" 1029-MS 5/4 x 4-1/4 x 47-3/4" 1033-MS 56-1/4"...

  • Page 20: Side Walls

    STOP DO NOT IF YOU HAVE MONKEY BARS, YOUR SIDE WALLS WILL BE CONSTRUCTED AS BELOW. FORT WITHOUT MONKEY BAR OPTION SIDE WALLS IMPORTANT! LEFT SIDE CONTINUE TO PAGE 19. BALLUSTERS INSTALLED SWING SIDE IF YOU HAVE MONKEY BARS, YOUR SIDE WALLS WILL BE CONSTRUCTED AS BELOW. FORT WITH MONKEY BAR OPTION SIDE WALLS MONKEY BAR / LEFT SIDE...
  • Page 21 SWING SIDE WALL FORT WITHOUT MONKEY BAR OPTION 1 x 4 x 56-1/2" 1037-MS Flush " 16-1/4 5/8 x 3-1/4 x 34-1/2" 2324-MS 35-1/4" 35-1/4" 1 x 4 x 56-1/2" 1-1/4" Wood 1037-MS 8-1/8" 8-1/8" Screws CENTER SWING SIDE WALL FORT WITHOUT MONKEY BAR OPTION Use 2324-MS as a 3-1/4"...
  • Page 22 FORT WITHOUT MONKEY BAR OPTION LEFT SIDE WALL 1 x 4 x 56-1/2" 1037-MS Flush " 3-1/4 5/8 x 3-1/4 x 34-1/2" 2324-MS 35-1/4" 35-1/4" 1-5/8" 1-5/8" 1 x 4 x 56-1/2" 1037-MS 1-1/4" Wood Screws CENTER LEFT SIDE WALL FORT WITHOUT MONKEY BAR OPTION Use 2324-MS as a 3-1/4"...
  • Page 23 FORT WITHOUT MONKEY BAR OPTION SIDE WALLS LEFT SIDE 3" Wood Screws x 16 Flush Use two (2) 3" Wood Screws. Flush SWING SIDE STOP YOU MAY NOW CONTINUE REGULAR ASSEMBLY OF YOUR PLAYSET ON PAGE 24.
  • Page 24 SWING SIDE WALL FORT WITH MONKEY BAR OPTION 1 x 4 x 56-1/2" 1037-MS Flush " 16-1/4 5/8 x 3-1/4 x 34-1/2" 2324-MS 35-1/4" 35-1/4" 1 x 4 x 56-1/2" 1-1/4" Wood 1037-MS 8-1/8" 8-1/8" Screws CENTER SWING SIDE WALL FORT WITH MONKEY BAR OPTION Use 2324-MS as a 3-1/4"...
  • Page 25 FORT WITH MONKEY BAR OPTION SIDE WALLS MONKEY BAR / LEFT SIDE 1 x 4 x 56-1/2" 3" 1037-MS Wood Screws x 16 1 x 4 x 56-1/2" 1037-MS Flush Use two (2) 3" Wood Screws. Flush SWING SIDE STOP ATTENTION: MONKEY BAR OPTION OWNERS LEFT SIDE WALL IS SHOWN WITH BALLUSTERS THROUGHOUT THE REMAINDER OF THIS MANUAL.

  • Page 26: Upper Arms

    This space intentionally left blank. FORT UPPER ARMS 2 x 4 x 51" Install bolts fi rmly, but do not fully tighten. 1/4" Pre-Drill all 1009-MS Re-adjustment will be neccessary. holes 1-1/2" DEEP. 4” Hex Bolt Do not drill through. LEFT SIDE 2 x 6 x 84"...
  • Page 27 FORT INSTALL LEGS LEFT SIDE * Note - 5-1/4” Hex Bolt For Safety two people are required to carefully roll fort over. Plastic 5-1/2“ Hex Bolt Angled Plug Plastic 5-1/4” Hex Bolt with Angled Plug Lock washer and Flat Washer 5-1/2”...
  • Page 28 FORT BOTTOM SUPPORTS DO NOT OVER-TIGHTEN LAG BOLTS SIDE VIEW Hex Bolt 2 x 6 x 84" T-Nut LEFT SIDE 1088-MS Lag Bolt 3-1/2” Lag Bolt T-Nut 2 x 4 x 51" 1009-MS 4” Hex Bolt T-Nut 3-1/2” Lag Bolt 1/4"...
  • Page 29 FORT INSTALL LEGS * Note - For Safety two people are required to carefully roll fort over. Remove and re-insert each 5-1/4” Hex Bolt (one at a time) through the holes from the opposite direction - this time using a Lock Washer, Flat Washer and T-Nut Install And Tighten Into T-Nuts At This Time.

  • Page 30: Back Side

    FORT STEP LADDER 2-1/2" Wood Screws (x 22) Angled End 2 x 4 x 59-1/8" 2316-MS 1053-MS 2 x 4 x 15" Flush 2315-MS 2 x 4 x 67-5/8" POSITION LADDER TOP BLOCK 1053-MS AS SHOWN TO LADDER RAIL. 2 x 4 x 15-3/8" 1051-MS Back Back side...
  • Page 31 FORT STEP LADDER 2 x 4 x 15" 1053-MS 1-5/8” Screws (x3) 3” Wood 1053-MS Screws 2 x 4 x 15" Flush Lock Washer T-Nut Position Ladder Top Block beneath Deck End Board. Attach with three 1-5/8” Wood Screws. When installed, front edge of Ladder Flat Top Block (1053-MS) should be flush with 4-1/4”...

  • Page 32: Angle Brackets

    SWING BEAM SWING HANGERS 3“ Lag Screw (x24) Lock Washer (x24) Flat Washer (x24) 2003 2-3/4 x 5-3/8 x 94-1/2" 2314-MS SWING BEAM ANGLE BRACKETS 3-1/2” Hex Bolt Flat Washer Flat Washer Lock Nut 2023...
  • Page 33 SWING BEAM A-FRAME L-BRACKET Orient swing beam as shown. 2106-H Step 1 3” DO NOT OVER-TIGHTEN LAG BOLTS 3/16" x 2" DEEP Pre drill 5/16 x 3" Lag Bolt pilot holes. Step 2 5/16" Lock Washer 5/16" Flat Washer 2106-H Step 3 Install fasteners.
  • Page 34 A - FRAME ASSEMBLE 3-3/4” Hex Bolt Lock Washer Flat Washer 1017-MS 5/4 x 6 x 68-1/4” Pre-installed T-Nuts Add extra Flat Washers if bolt threads are underneath. protrude past T-Nuts. A - FRAME INSTALL NOTE: Ensure two to three threads are exposed past Lock Nut.
  • Page 35 A - FRAME INSTALL Pre-drill four 3/16” pilot holes, 2" DEEP. IMPORTANT! Drill-holes must be 3/16” 2" DEEP. A - FRAME INSTALL 5/16” x 3” Lag Bolt 5/16” Lock Washer 5/16” Flat Washer...
  • Page 36 SWING BEAM SUPPORT ASSEMBLE 2 x 4 x 43-1/2" 2311-MS SWING BEAM SUPPORT INSTALL TO BEAM Flat Washer Acorn Nut 10” Hex Bolt T- Nut Lock Nut Flat Washer Flat Washer 4” Hex Bolt 4” Hex Bolt Flat Washer Lock Nut Flat Washer...

  • Page 37: Swing Beam Assembly

    * TWO PEOPLE AND A STEP LADDER ARE RECOMMENDED FOR THIS STEP SWING BEAM ASSEMBLY INSTALL * USE CARE WHEN INSTALLING SWING BEAM ASSEMBLY SWING SIDE...
  • Page 38 INSTALL - STEP 1 SWING BEAM ASSEMBLY *Hint – Clamp swing beam assembly Flush in place while marking holes. SWING SIDE SAME MEASUREMENT SAME MEASUREMENT INSTALL - STEP 2 SWING BEAM ASSEMBLY Drill 9/16” holes through at marked locations. Confi rm Holes are in line. SWING SIDE...
  • Page 39 SWING BEAM ASSEMBLY INSTALL - STEP 3 T - Nut Add extra Flat Washers if bolt threads protrude past T-Nuts. Flat Washer Lock Washer 2-1/2" Hex Bolt 3" Hex Bolt Lock Flat Washer Flat Washer ROCK WALL 1 x 6 x 47-3/4" 41”...
  • Page 40 ROCK WALL LAY OUT PARTS - ROCK LOCATIONS After marking Rock positions, remove Rocks and drill 1/4” holes through Rock Wall Deck Boards using the marked hole locations. ROCK WALL INSTALL T-NUTS Turn all eleven 1026-MS panels over (lay on a soft but firm surface). Pound in 1/4”...
  • Page 41 ROCK WALL LAY OUT PARTS - ROCK LOCATIONS 1/4” x 1-1/2” Hex Head Bolts 1/4” Lock Washers 1/4” Flat Washers Return panels to face up position. Align Climbing Rocks back into position over their holes. 1026-MS 1 x 6 x 47-3/4" T-Nuts ROCK WALL INSTALL...

  • Page 42: Rope Ladder

    ROPE LADDER ASSEMBLE & INSTALL 2 x 6 x 84" 1088-MS Step 1 Feed Ropes up through holes in Upper Rope Arm ( 1088-MS ) and tie a double knot. 21-1/2" Step 2 Slide one Ladder Rung ( 1025-MS ) up the Ropes and tie a single knot in each rope.
  • Page 43 CLIMBING ROPE INSTALL 2 x 6 x84" 1088-MS OPTIONAL: Tie several single knots in locations to allow logical hand-grab points. 2 x 6 x 84" 1088-MS Step 1 Feed top of Climbing Rope through front of Upper Rope Arm ( 1088-MS ) and tie a double knot on the back side ( Fig.
  • Page 44 ROOF RAFTERS T-Nut x4 2 x 4 x 59-1/2" 1198-MS Lay out four rafter-halves (1198-MS) as shown. Pound in T-Nuts. ROOF RAFTERS 3" Wood Screw 3" Wood Screw Flush at peak Flush at peak 2 x 4 x 59-1/2" 1198-MS STEP 2 STEP 1 3-1/2"...
  • Page 45 ROOF ROOF BOARDS 2-1/2" Wood Screws Center roof panels on rafters. Ensure equal overhang on both sides; about 7/8". 5/4 x 6 x 47-3/4" 1203-MS 7/8" 7/8" Maintain 43-3/8" dimension between rafters. 43-3/8" Flush 3/8" ROOF ROOF BOARDS Insert panels fully 5/4 x 6 x 47-3/4"...
  • Page 46 RAFTER MIDDLE SUPPORT ROOF WARNING! Install screws fl ush with roof board to avoid protruding below roof. Flush Flush 1-5/8" Wood Screw 1 x 3 x 58-1/2" 1204-MS 1-1/4" Wood Screws x 10 ROOF ASSEMBLE WARNING! Install screws fl ush with roof 1-1/4"...
  • Page 47 ROOF ROOF BOARDS WARNING! Install screws fl ush with roof 5/4 x 6 x 47-3/4" board to avoid protruding below roof. 1203-MS 2-1/2" Wood Screws 1-1/4" Wood Screws x 56 x 28 INSTALL FOURTEEN (14) PANELS. ROOF TRIM & RAFTER SUPPORT 3/8 x 6 x 16"...
  • Page 48 SWINGS INSTALL Clip a Spring Clip at the end of each Swing chain. Then, using the Spring Clips, attach the Swings to the swing brackets on the swing beam, as shown below. 2004 Attach Playset Plaque using One 1” Philips Head Screw (provided) at each corner of Plaque.
  • Page 49 TIRE SWING SUPPORT BUTTON HEAD BOLTS 2-3/4" Button Head 9/16" Drill through Screw x2 parts 1085-MS and 1033-MS. 5/4 x 6 x 67-1/2" 1085-MS Flat Washer 3-3/8" CENTER 1 x 4-1/4 x 47-3/4" 1033-MS TIRE SWING HANGER INSTALL * I M P O R T A N T * Two people may be required to install and tighten Lock Nuts.
  • Page 50 TIRE SWING ASSEMBLE Use a screwdriver to hold Eye Bolt in place when tightening Lock-Nut and Acorn-Nut. 8” Eye Bolt 2120 Flat Washer Fender Washer Lock-Nut Acorn-Nut Tighten Lock-Nut until three (3) threads are exposed. Use a wrench to tighten all Lock-Nuts and Acorn-Nuts.
  • Page 51 TIRE SWING ASSEMBLE & INSTALL Tire Swing Hanger Narrow End of Spring Clip DOWN Spring Clip 2004 2018 • Use a wrench to tighten Quick Clips securely closed. • Hold Quick Clip with pliers or screwdriver while tightening. Quick Clip x3 2020 8”...
  • Page 52 STAKES Stakes Flush with TOP. STAKE STAKE STAKE 1015-MS 1-1/2 x 1-1/2 x 17" 2-1/2" Wood Screws (x4) STAKE STAKE STAKE Pound in Stakes (1015-MS) at 45 degree angle. Stakes Flush with Make sure all base pieces, uprights and slide SIDES.
  • Page 53 SLIDE SLIDE MOUNT INSTALL 1-5/8" Wood Screw (x2) 1 x 6 x 41-1/2" 1-3/4" 2312-MS 2 x 4 x 15-3/8" 1051-MS 1051-MS 2 x 4 x 15-3/8" Flush Position Slide Mount beneath Deck End Board. Attach with two 1-5/8" Wood Screws as shown. 4"...
  • Page 54 SLIDE MEASURE 5/4 x 6 x 47-3/4" 2 x 4 x 15-3/8" 1 x 6 x 41-1/2" 1085-MS 1051-MS Flush 2312-MS 3-3/4" Slide 2015 Slide SLIDE DRILL Drill 1/8” holes at both dimples through Slide and 2312-MS into 1051-MS (1 inch deep). 5/4 x 6 x 41-1/2"...

  • Page 55: Mounting Screws

    SLIDE MOUNTING SCREWS 2-1/2" Pan Head Wood Screw (x2) 1/4" x 1" Fender Washer (x2) 5/4 x 6 x 41-1/2" 2312-MS SLIDE SURFACING MATERIAL Apply Surfacing Material at recommended depth, or deeper.

  • Page 56: Safety Handles

    SAFETY HANDLES INSTALL Attach 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 the customer - depending on the age of the child, etc. 2007 1/8"...

  • Page 57: Steering Wheel

    INSTALL ROPE LADDER BOTTOM SUPPORT GUSSETS DO NOT OVER-TIGHTEN LAG BOLTS 4" Lag Bolt 1/4" x 1-1/2" Lock Washer DEEP Pre-Drill. Flat Washer 1/4" x 1-1/2" DEEP Pre-Drill. 1/4" x 1-1/2" DEEP Pre-Drill. 2 x 4 x 18" 1020-MS 3-1/2" Lag Bolt Flat Washer DO NOT OVER-TIGHTEN LAG BOLTS Lock Washer...
  • Page 58 TELESCOPE INSTALL 1-1/4" Screws Telescope 2073 Telescope Bracket Any Top Rail STOP YOU HAVE FINISHED YOUR BASE PLAYSET. IF YOU HAVE MONKEY BARS PROCEED TO NEXT PAGE.
  • Page 59 INSTALL TOP LADDER SUPPORTS 2 x 4 x 43-1/2" 2322-MS NOTE: Part 2322-MS (43-1/2") is from Monkey Bar Kit. TOP LADDER SUPPORTS INSTALL 2 x 4 x 43-1/2" 2322-MS T-Nut 5" Hex Bolt (x2) Flat Washer Flat Washer T-Nut 5" Hex Bolt T-Nut 8-1/4"...

  • Page 60: Left Side

    MONKEY BAR INSTALL POSITION * USE CARE WHEN INSTALLING MONKEY BAR ASSEMBLY LEFT SIDE * TWO PEOPLE AND A STEP LADDER ARE RECOMMENDED FOR THIS STEP MONKEY BAR INSTALL - STEP 1 *Hint – Clamp Monkey Bar Assembly 4-1/2" in place while marking holes. LEFT SIDE Mark two drill-holes.
  • Page 61 MONKEY BAR INSTALL - STEP 2 SEE PAGE 8 LEFT SIDE Drill-Through 1/4" marked locations. Re-Drill through using 1/2" bit from outside of SEE PAGE 8 frame at each support hole location. MONKEY BAR INSTALL - STEP 3 T-Nut 2-1/2" Hex Bolt Flat Lock Washer...
  • Page 62 MONKEY BAR BALUSTERS LEFT SIDE 1-1/4" Wood Screws INSTALL THIS Use 2324-MS as a BALUSTER FIRST. 3-1/4" spacer. 5/8 x 3-1/4 x 34-1/2" 3" 2324-MS INSTALL THIS BALUSTER FIRST. Flush Install each 2324-MS fl ush at bottom. CENTER Locate middle spacer centered between Monkey Bar vertical supports.

  • Page 63: Warranty

    Systems. Labor warranty does NOT apply to Do-It-Yourself playset kits or kits installed by a third party. Backyard Play Systems will repair, replace or pay for the affected part at our discretion. In no event shall Backyard Play Systems pay the cost of labor or installation or any other costs related thereto.
  • Page 64 Backyard Play Systems does not assume, or authorize any person to assume for us, any other liability in connection with the sale of our prod- ucts.

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