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Discovery Centers DC-5XLG-P Assembly Instructions Manual

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ASSEMBLY INSTRUCTIONS
07-17-17

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  • Page 1 ASSEMBLY INSTRUCTIONS 07-17-17...
  • Page 3 This will allow UltraPlay to have a record of your purchase in case of warranty claims. For more information on Discovery Centers and UltraPlay products, please do not hesitate to give us a call or visit uplaytoday.com & ultraplay.com.
  • Page 4 See Figure 1 below (example: a Slide from a 6 foot deck requires 6 feet of clear space with resilient surfacing in front of its exit). Discovery Centers slides are 4 feet or shorter; therefore, the slide exit use zone is 72 inches.
  • Page 5 GEN ER A L C OM ME RC I AL P L AYG RO U ND SAF ET Y G UID E LINE S ( Pa ge 2 of 5 ) Never overlap the safety zones of adjacent equipment. All separate play equipment must have its own safety zone, and these cannot overlap.
  • Page 6 GEN E R AL C OMM E RC I AL P L AYG RO U ND S AF E T Y G U IDE LIN ES (Pa g e 3 of 5 ) CATCH POINT & PROTRUDING HARDWARE: There should be no dangerous pieces of hardware, such as protruding bolt ends and narrow gaps in metal connections or open “S”...

  • Page 7: Routine Maintenance

    Following are some regular maintenance areas of note: • Check for and repair damage caused by wear or vandalism, a major factor in injury causing situations. • Proper maintenance of Discovery Centers equipment requires regular tightening of all bolts, nuts, set screws and other hardware.
  • Page 8 GE N E R A L C OMM ERC I AL P L AYG RO U N D SA FE T Y GU ID ELIN ES (Pa g e 5 of 5 ) • Check for missing, damaged, or loose swing seats. Check rubber seats for wear, sharp edges/points, scorching, or burn damage.

  • Page 9: Limited Warranties

    LIMITED WARRANTIES Ten Years Five Years One Year • Upright Posts • Moving Parts • Rotomolded Plastic • Post Caps • Freestanding and Components • Hardware other components • Blowmolded Plastic Components • Ground Mount Metal Parts Materials and Workmanship Materials and Workmanship Materials and Workmanship All warranties specifically exclude damage caused by man-made or natural disasters, vandalism, negligence,...
  • Page 10 TEN-YEAR LIMITED WARRANTY ON UPRIGHT POSTS, CAPS, AND HARDWARE UltraPlay provides a limited warranty on Discovery Centers metal upright posts, caps, and hardware to be free from defects in materials or workmanship against structural failure which causes the product to become unfit for its intended use, subject to normal usage and installation, for a period of 10 years from the date of shipment to the original customer.

  • Page 11: Cl A I M Proc E D U R E

    CL A I M PROC E D U R E Claim Procedure: To make a warranty claim, send your written statement of claim, photographs of defective equipment, and the original purchase invoice or invoice number to: Discovery Centers Customer Service 1675 Locust Street...
  • Page 12 (02-07-0057) (ZBAL-8) South Fork (Single Deck) [UPLAY-001-P/N] Ultraplay offers a variety of playground solutions to meet your specifi c needs. Check out UplayToday by UltraPlay in addition to other Discovery Centers playgrounds for your future projects. at www.ultraplay.com or www.uplaytoday.com.

  • Page 13: General Installation Guidelines

    IMPORTANT! Please read the entire Installation Instructions packet before beginning the installation. UltraPlay has designed Discovery Centers to take advantage of all Consumer Product Safety Commission (CPSC) and ASTM guidelines in force at the time of purchase in an effort to prevent playground accidents. However, because studies have shown most playground injuries result from accidental falls, you, as the new owner of this equipment are responsible for providing an adequately resilient play surface under and around all playground equipment.

  • Page 14: Tools Required

    Inquire with local contractors for appropriate recommendations. 6. Begin your Discovery Centers installation by erecting the decks as shown within the following instructions. Once all decks are installed, components such as slides, climbers, etc., can be connected per their respective assembly instructions.

  • Page 15: Safety During Installation

    Finally, if you should have any questions regarding the proper installation of this equipment, please contact UltraPlay at: UltraPlay Discovery Centers Customer Service 1675 Locust Street, Red Bud, IL 62278 Phone:1-800-458-5872 • Fax: 1-618-282-8202...
  • Page 16 GEN E R A L I N STA L LATI O N G U I D ELI NE S ( Pa g e 4 of 4) The Discovery Center is a modular play system that uses a grid system for the playground layout. It is very important to spend a few minutes before beginning the installation to ensure that components are inventoried and organized properly.
  • Page 17 TOO L S R E QUI R ED UTILITY KNIFE LEVEL MEASURING TAPE POST TIGHTING “T” TOOL TORX HEAD (included) WRENCHES/BITS 4LB HAMMER RUBBER MALLET (included) 3/8” 13mm ALAN HEAD BITS WRENCH 17mm DRILL MASONRY DRILL BIT (included) (included) Ul traPlay Play Systems LOCTITE 800.458.5872 •...

  • Page 18: Hardware Reference

    HAR D WAR E R EF E R ENCE M10 B.H.C.S. Bolts NOTE: Your play structure may not use all hardware listed 13mm 20mm 25mm 30mm 35mm 40mm 45mm 50mm 60mm 70mm 80mm 1/2” 1” 1-3/16” 1-3/8” 1-9/16” 1-3/4” 2” 2-3/8”...
  • Page 19 USE ZO NE MINIMUM USE ZONE* REQUIRED TOP VIEW * The USE ZONE is the area beneath and immediately adjacent to a play structure or equipment that is designed for unrestricted circulation around the equipment and on whose surface it is predicted that a user would land when falling from or exiting the equipment.
  • Page 20 31’ IMPORTANT: Never install play equipment over hard, unresilient surfaces such as 11’6” asphalt, concrete or compacted earth. It is TOP VIEW the owner’s responsibility to ensure the “minimum area required” contains an appropriate amount of resilient material to cushion accidental falls. 7’6”...

  • Page 21: Top View

    DECK P L AC EM E N T TOP VIEW Circles indicate threaded insert locations Vine Climber Short Slide Double Deck Note the position Platform of the square holes Bench Panel Ul traPlay Play Systems 800.458.5872 • www.ultraplay.com...

  • Page 22: Site Preparation

    FO OTI N G DETA I L - G RO U ND S P I K E S Instructions: 4lb Hammer 1. With Footers in position, secure Lower Post each footer to the ground using (2) ground spikes. NOTE: A 4 lb. hammer may be Install ground spikes angled inward as shown in illustration.
  • Page 23 FOOT IN G D E TA I L - C O NCRE T E A NCH OR S Instructions: 1. With Extension Footer in position, LowerPost mark hole position. Remove 2” Extension Footer and drill Extension 2-1/2”” Rubber (2) 3/8” Dia. x 2” deep holes Footer Tiles into concrete to receive anchor.
  • Page 24 FO OT ING DE TA I L - I NG RO U ND FO OTER S Instructions: Lower Post 1. Bolt Extenson Footer and Inground Footer together using (2 )M10 x 20mm (3/4”) BHCS Bolts and (2) M10 Lock Nuts. (2) M10 x25mm SURFACING Refer to Hole/Footer Location on...
  • Page 25 STEP 1 - C ON N EC T FO OT ERS TO LOW ER P OSTS Parts List Letter Description Quantity Part Number Lower Posts Footer - 8” 02-08-0134 Footer - 2” 02-08-0135 Hardware Complete 33-12-1021 M10 x 25mm(1”) BHCS Bolt 33-11-0003 M10 Lock Nut 33-11-0400...
  • Page 26 STE P 2 - C ON N E C T P LATFO RM M O U N TI NG BR AC K ET TO PL ATFORM Parts List Letter Description Quantity Part Number Platform 02-08-0022 Platform/Slide Mounting Bracket 02-08-0120 Hardware Complete 33-12-1008 M10 x 25mm( 1”) BHCS Bolt 33-11-0003...

  • Page 27: Front View

    STEP 3 - ATTAC H EXT ENSI O N P O STS AND FOOT ER PL ATE S TO PLAT FO RM Parts List Letter Description Quantity Part Number Extension Post 02-08-0118 Footer Plate 02-08-0122 Hardware Complete 33-12-1008 M10 x 35mm(1-3/8”) BHCS Bolt 33-11-0005 M10 Lock Nut 33-11-0400...
  • Page 28 STE P 4 - C ON NE C T B ENC H PANEL AN D P LAT FOR M TO DE C K 1 Parts List Letter Description Quantity Part Number Bench Panel 02-08-0010 Deck A 02-08-0006 Lower Post Cover - 7.5” Long 02-08-0050 Number Lower Post - 18”...
  • Page 29 STE P 5 - I NSTA L L D EC K 2 Square Holes Parts List Letter Description Quantity Part Number Lower Post Cover - 15.38” 02-08-0028 Deck A 02-08-0006 Number Lower Post - 31.5” Long 02-08-0110 Lower Post - 47.2” Long 02-08-0112 Square Holes...
  • Page 30 STEP 6 - I N STA L L D E C K 3 Parts List Square Holes Letter Description Quantity Part Number Lower Post Cover - 22.88” 02-08-0029 Deck B 02-08-0041 Number Lower Post - 31.5” Long 02-08-0110 Lower Post - 73.75” Long 02-08-0113 Deck 2 Ul traPlay Play Systems...
  • Page 31 STEP 7 - I N STA L L D E C K 4 Square Holes Parts List Letter Description Quantity Part Number Lower Post Cover - 30.25” 02-08-0030 Deck F 02-08-0054 Number Lower Post - 39.4” Long 02-08-0111 Lower Post - 47.2” Long 02-08-0112 Deck 3 Ul traPlay Play Systems...
  • Page 32 STEP 8 - I N STA L L STO R E FRO NT PANE L Parts List Letter Description Quantity Part Number Lower Post Cover - 37.38” 02-08-0031 Store Front Panel 02-08-0016 Number 11,12,13 Lower Post - 47.2” Long 02-08-0112 Ul traPlay Play Systems 800.458.5872 •...
  • Page 33 STEP 9 - I N STA L L “ X ” PA NE L AND D OU BLE DE C K Parts List Letter Description Quantity Part Number X Panel 02-08-0017 Double Deck 02-08-0007 Deck 2 Ul traPlay Play Systems 800.458.5872 •...
  • Page 34 STE P 10 - I NSTA L L TO U CH M AT H PAN EL Parts List Letter Description Quantity Part Number TouchMath Panel w/ Inserts 02-08-0047 Upper Post Covers - 7.38” 02-08-0033 Upper Post - 33.46” 02-08-0132 Ul traPlay Play Systems 800.458.5872 •...
  • Page 35 STE P 11 - I N STA LL C LI M B ER H AND H O LD B RAC KE T Parts List Letter Description Quantity Part Number Climber Handhold Bracket 02-08-0102 TouchMath Panel Ul traPlay Play Systems 800.458.5872 • www.ultraplay.com...
  • Page 36 STEP 12 - I NSTA L L HA ND H O L D B R AC KE T AND CLOC K PA NE L Parts List Letter Description Quantity Part Number Clock Panel w/ Inserts 02-08-0048 Climber Handhold - EVEN 02-08-0003 Upper Post Cover - 7.38”...
  • Page 37 STEP 13 - I N STA LL SL I D E H O O D Parts List Letter Description Quantity Part Number Slide Hood A 02-08-0002 Upper Post - 34.6” Long 02-08-0115 Clock Panel Square Holes TouchMath Panel Ul traPlay Play Systems 800.458.5872 •...
  • Page 38 STEP 14 - I N STA LL C O LO RS / S H AP E S PANE L AND RIGH T H AN D HO LD Parts List Letter Description Quantity Part Number Colors/Shapes Panel 02-08-0014 Climber Handhold - EVEN 02-08-0003 Upper Post - 34.6”...
  • Page 39 STEP 15 - ATTAC H B A RR I ERS A ND S L I DE HO OD Parts List Letter Description Quantity Part Number Barrier Panel - RIGHT 02-08-0049 Barrier Panel - LEFT 02-08-0038 Inserts Slide Hood B 02-08-0053 on inside Upper Post - 57.5”...
  • Page 40 STEP 16 - ATTAC H W I ND OW PANE L Parts List Letter Description Quantity Part Number Upper Post Cover-7.38” Long 02-08-0033 Window Panel 02-08-0015 Upper Post - 57.5” Long 02-08-0117 Ul traPlay Play Systems 800.458.5872 • www.ultraplay.com...
  • Page 41 STE P 17 - AT TAC H G EA R PANEL Parts List Letter Description Quantity Part Number Gear Panel 02-08-0012 Upper Post - 57.5” Long 02-08-0117 Window Barrier Panel Panel Ul traPlay Play Systems 800.458.5872 • www.ultraplay.com...
  • Page 42 STE P 18 - ATTAC H P O ST COV E R S AND L EAF ARC HWAY Parts List Letter Description Quantity Part Number Post Cover - 28.88” Long 02-08-0035 Post Cover - 21.38” Long 02-08-0134 Post Cover - 7.38” Long 02-08-0033 Leaf Archway 02-08-0008...
  • Page 43 STE P 19 - ATTAC H SLI D E FO OTE R P L AT E TO STR A IG HT S L IDE Parts List Letter Description Quantity Part Number Short Straight Slide 02-08-0040 Platform/Slide Mounting Bracket 02-08-0120 Extension Post - 8” Long 02-08-0118 Footer Plate 02-08-0122...
  • Page 44 STE P 20 - AT TAC H STR AI G H T SLI D E TO D E CK Parts List Letter Description Quantity Part Number Hardware Complete 33-12-1004 M10 x 60mm(2-3/8”) BHCS Bolt 33-11-0007 M10 Lock Washer 33-11-0201 M10 Flat Washer 33-11-0200 1.
  • Page 45 STE P 21 - AT TAC H V I NE CL I M B E R B R AC K ET TO D EC K Parts List Letter Description Quantity Part Number Vine Climber Bracket 02-08-0106 Hardware Complete 33-12-1003 M10 x 25mm(1”) BHCS Bolt 33-11-0003 M10 Lock Washer 33-11-0201...
  • Page 46 STEP 22 - AT TAC H FO OT E RS TO V I NE C LI MB ER Parts List Letter Description Quantity Part Number Vine Climber 02-08-0024 Small Climber Extension Post (2”) 02-08-0107 Large Climber Extension Post (8”) 02-08-0108 Footer Plate 02-08-0122 Hardware Complete...
  • Page 47 STEP 23 - AT TAC H V INE CL I M B E R TO D EC K MOU N TIN G B RACK ET Parts List Letter Description Quantity Part Number Hardware Complete 33-12-1003 M10 x 20mm(3/4”) BHCS Bolt 33-11-0002 M10 Lock Washer 33-11-0201...
  • Page 48 STEP 24 - ATTAC H SL I D E FO OTE R P L ATE TO C URVED S LID E Parts List Letter Description Quantity Part Number Curved Slide 02-08-0020 Platform/Slide Mounting Bracket 02-08-0120 Extension Post - 8” Long 02-08-0118 Footer Plate 02-08-0122...
  • Page 49 STEP 25 - AT TAC H C ENT E R S U P P O RT P OST TO C URV E D S L IDE Parts List Letter Description Quantity Part Number Curved Slide Center Support Post 02-08-0123 Hardware Complete 33-12-1017 M10 x 20mm(3/4”) BHCS Bolt 33-11-0002...
  • Page 50 STEP 26 - AT TAC H C U RV E D SL I D E TO D EC K Parts List Letter Description Quantity Part Number Hardware Complete 33-12-1017 M10 x 80mm(2-3/4”) BHCS Bolt 33-11-0008 M10 Lock Washer 33-11-0201 M10 Flat Washer 33-11-0200 Slide Slide...

  • Page 51: Side View

    STEP 27 - AT TAC H B O NG O S SU P P O RT BR AC KE T TO B ON GO S Parts List Letter Description Quantity Part Number Bongos 02-08-0025 Bongos Support Bracket 02-08-0103 Mounting Bar 02-08-0126 Hardware Complete 33-12-1005...
  • Page 52 STEP 28 - AT TAC H B O NG O S M O U NT I NG B RAC KE T TO D EC K Parts List Letter Description Quantity Part Number Bongos Mounting Bracket 02-08-0104 Hardware Complete 33-12-1005 M10 x 20mm(3/4”) BHCS Bolt 33-11-0002 M10 Lock Washer 33-11--0201...
  • Page 53 STEP 29 - AT TAC H B O NG O S TO M O U NT IN G B RAC K ET Parts List Letter Description Quantity Part Number Hardware Complete 33-12-1005 M8 x 25mm(1”) BHCS Bolt 33-11-0103 M8 Barrel Nut 33-11-0501 Clock Panel...
  • Page 54 ST EP 30 - ATTAC H R AI NWH EE L MO U NT IN G B RAC K ET TO DE C K Parts List Letter Description Quantity Part Number Rainwheel Mounting Bracket 02-08-0127 Hardware Complete 33-12-1006 M10 x 20mm(3/4”) BHCS Bolt 33-11-0002 M10 Lock Washer 33-11-0201...
  • Page 55 STEP 31 - AT TAC H RAI NW HEE L TO M O UN TI NG BRAC K ET Parts List Letter Description Quantity Part Number Rainwheel 02-08-0026 Plastic Spacer 02-08-0129 Rainwheel Bushing 02-08-0128 Yellow plastic Cap 02-08-0037 Hardware Complete 33-12-1006 M8 Flat Washer 33-11-0300...
  • Page 56 STEP 32 - AT TAC H 9 0 D E G RE E A ND 18 0 D EG R E E CO NN EC TORS Parts List Letter Description Quantity Part Number 180 Degree Panel Connector 02-08-0101 90 Degree Panel Connector 02-08-0100 Hardware Complete 33-12-1012...
  • Page 57 STEP 33 - AT TAC H T E L E S CO P E TO P OST # 9 Parts List Letter Description Quantity Part Number Mounting Plate (2 parts) 02-08-0133 Mounting Bracket 02-08-0105 Figure 1 Telescope 02-08-0005 Hardware Complete 33-12-1001 M10 x 50mm(2”) BHCS Bolt 33-11-0010...
  • Page 58 STEP 34 - AT TAC H P O ST C AP S Parts List Letter Description Quantity Part Number Post Cap 02-08-0027 Hardware Complete 33-12-1025 M10 x 50mm(2”) BHCS Bolt 33-11-0010 Figure 2 Figure 1 1. Apply Loctite adhesive to Bolts(B). 2.
  • Page 59 STEP 35 - AT TAC H RO O F Parts List Letter Description Quantity Part Number Roof 02-08-0001 Hardware Complete 33-12-1009 M5 x76mm (3”) Self-tapping Screw 33-11-0600 1. Lower Roof(A) onto Uprights. NOTE: Use Inside Sockets Side View 2. Centered horizontally with Upright, measure 1”(25mm) up from bottom of Roof(A) and drill 1/8”pilot hole through Roof and into Upright.
  • Page 60 STE P 36 - ATTAC H FO OT ER COV ER S Parts List Letter Description Quantity Part Number Footer Cover 02-08-0009 Hardware Complete 33-12-1016 M8 x 40mm(1-9/16”) BHCS Bolt 33-11-0106 M8 Lock Washer 33-11-0301 M8 Flat Washer 33-11-0300 M8 Barrel Nut 33-11-0501 Upright Post Cover...

  • Page 61: Comp One N T Pa Rt Nu M B Ers

    COMP ONE N T PA RT NU M B ERS* Letter Description Part Number Quantity Letter Description Part Number Quantity Footer Covers 02-08-0009 Bongo Drum Mounting Bar 02-08-0126 Footers - 8” 02-08-0134 (0135-2”) Bongo Drum Support Bracket 02-08-0103 Lower Post - 17.32” Long 02-08-0109 Bongo Drum Mounting Bracket 02-08-0104...

  • Page 62: Component List

    COMPONENT LIST Letter Description Quantity Footer Covers Footers - 8” Lower Post - 18” Long Lower Post - 47.2” Long Lower Post - 31.5” Long Lower Post - 73.62” Long Lower Post - 39.4” Long Upper Post - 33.46” Long Upper Post -57.48”...

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