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Backyard Play Systems 4143 Assembly Manual

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2491-SB
- NOTICE -
This playset product is not intended for public use. It is intended for
residential application and is not warranted for public or commercial use.
STOP!
STOP!
Call Us First!
DO NOT RETURN TO STORE.
For immediate help with assembly or product information
call our toll-free number:
1-866-890-2211
April through October M - F 8:00 AM to 6:00 PM EST
Saturday 8:30 AM to 4:30 PM EST
November through March M - F 8:00 AM to 5:00 PM EST
or email:
customerservice@backyard-play.com
Our staff is ready to provide assistance.

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  • Page 1 2491-SB - NOTICE - This playset product is not intended for public use. It is intended for residential application and is not warranted for public or commercial use. STOP! STOP! Call Us First! DO NOT RETURN TO STORE. For immediate help with assembly or product information call our toll-free number: 1-866-890-2211 April through October M - F 8:00 AM to 6:00 PM EST...

  • Page 3: Before You Begin

    2491-SB 2/19/2014 Model: Customer Service Backyard Play Systems 4141, 4142, 4143, 4144, 1-866-890-2211 1000 Ternes 4145, 4146, 6202, 6203, Playset Monroe, MI 4816 6204, 6205, 6206, 6207, Recommended for Ages 3 to 11 - BEFORE YOU BEGIN - Tools Required Adult Assistance required First...
  • 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). This playset is recommended for children (3) through (11) years of age.

  • 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 2 x 4 x 47-7/8" 2 x 4 x 96" 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” 1021-ST 1023-ST 5/4“ x 4”..........1” x 3-1/2” 2 x 4 x 51"...
  • Page 12 Angle Bracket Plate Telescope Swing Beam 90 Plate Swing Beam Angled Plate Left 2448 2073 2485 2449 Steering Wheel Swing Beam Angled Plate Right Swing Beam Flat Plate 2447 2411 2603 Spring Clip Swing Hanger Plastic Hole-Plug Angled Angle plug 2433 2004 Safety Handle...
  • Page 13 A C T U A L S I Z E S H O W N 3/8” LAG BOLT WOODSCREWS x70 x58 x8 x140 1-1/4" 1-5/8" 1-3/4" 2" 2-1/2" 3" 3" 3-1/2" 4" 1/4" SAFETY HANDLE HDW. 3/8" FLAT WASHER TRUSS HEAD SCREW 1-1/2"...
  • Page 14 A C T U A L S I Z E S H O W N 4-1/2" 5" 5-1/4" 5-1/2" 6" 3/8" 3/8" 3/8" 3/8" 3/8" 3-3/4” 4" 2-1/2" 2" 1-1/2" 1-1/4" 3/8" 3/8" 3/8" 3/8" 3/8" 3/8"...
  • Page 15 A C T U A L S I Z E S H O W N 3-3/4" 4-1/2" 6-1/2" 9" 7" 3/8" 3/8" 3/8" 3-1/2" 3/8" 3/8" TORQUE WASHER 3/8" 3/8" 3/8"...
  • Page 16 SET-UP ORIENTATION BACK SIDE 6' SAFETY AREA 29'-1" SLIDE 14'-11" 10'-11" 13'-4" HEIGHT LEFT SIDE RIGHT SIDE SWING 15'-8" 13'-4" ROCK WALL 6' SAFETY AREA 27'-8" FRONT SIDE SET-UP ORIENTATION BACK SIDE BASE PLAYSET 6' SAFETY AREA WITH 29'-1" MONKEY BARS SLIDE 14'-11"...

  • Page 17: Parts Layout

    FORT PARTS LAYOUT 3 x 3 x 44-1/8" *IMPORTANT! 5/4 x 4-1/4 x 47" 5/4 x 6 x 47" 2310-W 1093-ST 1083-ST Lay Out Corner Posts 5/4 x 6 x 41-3/4" as shown. 2312-ST LEFT Note 2547-W hole location. FRONT 2547-W 3 x 3 x 44-1/8"...
  • Page 18 FORT CORNER POSTS / FLOOR Outside of Posts Pre- t deck boards so 48" they are evenly spaced Make sure corner before installing screws. 1 x 6 x 41-3/4" posts are squared to 2312-ST measurements shown. 5/4 x 6 x 47" Center boards between 1083-ST 48"...

  • Page 19: Side Walls

    FORT TENT SIDE RAILS LEFT SIDE Lock Install bolts rmly, but do not fully tighten. Washer Flat Re-adjustment will be neccessary. Washer 2 x 4 x 96" 1023-ST 4” Hex Bolt 4” Hex Bolt Flat Washer Lock Washer RIGHT SIDE FORT SIDE WALLS Keep 56-1/2"...
  • Page 20 FORT UPPER ROPE ARM Orient Rope Arm parts 2540-ST as shown. Assemble using 1-3/4" screws, 2" Hex Bolt, Washers and T-Nut. Keep holes, ends and corners of both 2540-ST aligned and ush during assemby. Tighten the screws and the bolt securely. 1-3/4"...
  • Page 21 FORT UPPER ARMS LEFT SIDE Install bolts rmly, but do not fully tighten. Re-adjustment will be neccessary. 4” Hex Bolt 5/4 x 6 x 84" 2540-ST x1 Pre-Assembled 2 x 4 x 51" 1009-ST PRE-DRILL 1/4" x 1-1/2" DEEP before installing lag bolts.
  • Page 22 FORT INSTALL LEGS LEFT SIDE * Note - 5-1/4” Hex Bolt For Safety two people are required to carefully roll fort over. 5-1/2” Hex Bolt Plastic Angled Plug 5-1/4” Hex Bolt with Plastic Angled Plug Lock washer and Flat Washer 5-1/2”...
  • Page 23 FORT BOTTOM SUPPORTS SIDE VIEW LEFT SIDE 2 x 4 x 51" T-Nut 1009-ST T-Nut 4" Hex Bolt Lock Washer T-Nut 4" Hex Bolt Flat Washer 1088-ST RIGHT SIDE 2 x 6 x 84" FORT DECK / TIRE SUPPORT LEFT SIDE HINT: Temporarily hold 1085-ST in place under deck with (3) 1-5/8"...
  • Page 24 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 25: Back Side

    FORT STEP LADDER 2-1/2" Wood Screws (x 22) Angled End 2 x 4 x 59-1/8" 2316-ST 1053-ST 2 x 4 x 15" Flush 2315-ST 2 x 4 x 67-1/8" POSITION LADDER TOP BLOCK 1053-MS AS SHOWN TO LADDER RAIL. 2 x 4 x 15-3/8" 1051-ST Back Back side...
  • Page 26 FORT STEP LADDER 2 x 4 x 15" 1053-ST 1-5/8” Screws (x3) RIGHT SIDE 3” Wood 1053-ST 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-ST) should be flush with...
  • Page 27 FORT TENT VERTICAL SUPPORTS 2 x 4 x 69-1/2" 2546-ST LEFT SIDE 1. Pre drill 3/16" pilot holes through 2546-ST from inside (A). Center drill in counterbore. 2-1/2" Hex Bolt Lock Washer T-Nut Flat Washer 2" Hex Bolt 2. Drill 7/16" through holes Lock Washer through 2546-ST from Flat...
  • Page 28 SWING BEAM SWING HANGERS Lock Nut NOTE: Ensure two 2433 to three threads Lock Nut are exposed past Lock Nut. Flat Washer Flat Washer Torque Washer 6-1/2" Carriage Bolt 3-1/2 x 5-1/2 x 95" Torque Washer 2749-W 7" Carriage Bolts NOTE: You may need to tap bolts with hammer to get through holes.
  • Page 29 METHOD A SWING BEAM SUPPORT LEFT SIDE Flat Washer Lock Washer 6" Hex Bolt Smaller holes at TOP 2542-ST 3-3/8 x 3-3/8 x 56-1/4" RIGHT SIDE Flat Washer Lock Washer 6" Hex Bolt METHOD B SWING BEAM SUPPORT 6-1/2" Carriage Bolt LEFT Torque Washer SIDE...
  • Page 30 SWING BEAM A - FRAME T-Nut x2 2525-W 3 x 3 x 95" Rotate 2525-W 180 after installing T-Nuts. SWING BEAM ASSEMBLE 3-3/4” Hex Bolt Lock Washer Flat Washer Pre-installed T-Nuts 2506-ST are underneath. 5/4 x 6 x 70-3/4”...
  • Page 31 SWING BEAM HARDWARE 3-1/2" Carriage Bolt 2411 BACK SIDE RIGHT SIDE NOTE: Ensure two to three threads are exposed past Lock Nut. Flat Washer Lock Nut SWING BEAM HARDWARE 2499 DO NOT FULLY TIGHTEN CARRIAGE BOLTS AT THIS TIME 3-3/4" Carriage Bolt Lock Nut Flat Washer NOTE:...
  • Page 32 SWING BEAM HARDWARE 3-1/2 x 5-1/2 x 95" DO NOT FULLY TIGHTEN 2749-W CARRIAGE BOLTS AT THIS TIME Flat Washer Lock Nut 2448 4-1/2" Carriage Bolt NOTE: You may need to tap bolts with hammer to get through holes. Clean all debris from bolt threads before installing lock nuts.
  • Page 33 SWING BEAM ASSEMBLE Align holes and insert carriage bolt. Repeat where arrows are shown. 3-3/4" Carriage Bolt DO NOT FULLY TIGHTEN CARRIAGE BOLTS AT THIS TIME Flat Washer Lock Nut SWING BEAM ASSEMBLE 6-1/2" Carriage Bolt Torque Washer NOTE: You may need to tap bolts with hammer to get through holes.
  • Page 34 SWING BEAM INSTALL Position swing beam assembly resting upon plate and align with holes. 9" Carriage Bolt 6-1/2" Carriage Bolt NOTE: You may need to tap bolts with hammer to get through holes. Torque Washer Clean all debris from bolt threads before installing lock nuts.
  • Page 35 SWING BEAM INSTALL T-Nut Flat Washer Lock Washer 1-1/2" Hex Bolt RIGHT SIDE SWING BEAM ASSEMBLE & LEVEL Level swing beam and tighten all swing beam fasteners. Pre drill 1/4" x 1-1/2" deep hole. Tighten all fasteners 3" Lag Bolt Lock Washer Flat Washer...

  • Page 36: Final Assembly

    SWING BEAM FINAL ASSEMBLY 2-1/2" Pan Head Screw 1/4 x 1" Fender Washer FORT TENT TOP SUPPORT 2 x 4 x 47-7/8" 1021-ST LEFT SIDE 3" Wood Screws (x4) RIGHT SIDE...
  • Page 37 ROCK WALL LAY OUT PARTS - ROCK LOCATIONS 1 x 6 x 47" 41” 1084-ST centered Place and align parts 1026-ST parallel on ground. *Hint: Number the order of each part (1026-ST) for correct re-orientation, top to bottom. Mark parts on back side or use masking tape. Lay Out the Climbing Rocks (x12) in an attractive and practical fashion (6-GREEN, 6-YELLOW).
  • Page 38 ROCK WALL INSTALL T-NUTS Turn all eleven 1026-ST panels over (lay on a soft but firm surface). Pound in 1/4" T-Nuts (in separate bag 2452) at each hole location. 1/4” T-Nut x26 ROCK WALL INSTALL ROCKS 1/4” x 1-1/2” Hex Head Bolts 1/4”...
  • Page 39 ROCK WALL INSTALL 1-5/8" 2-1/2" Screws Screws 1 x 6 x 47" 1084-ST 1/2" Install top rock wall board ( 1084-ST ) ush to edge of fort oor using four 2-1/2" screws as shown. Secure rock wall cleat ( 2548-ST ) with two 1-5/8"...
  • Page 40 ROCK WALL INSTALL 1-5/8" Screws (x18) LEFT SIDE 1084-ST 1 x 6 x 47" RIGHT SIDE Continue securing rock wall cleat (2548-ST) with eighteen 1-5/8" screws through middle holes of rock wall boards. Make sure rock wall cleat (2548-ST) is pulled tightly against back rock wall boards.
  • Page 41 FORT SWING SIDE WALL RIGHT SIDE INSTALL THESE 5/8 x 3-1/4 x 33" 1-1/4" Wood Screws 2537-ST TWO BALUSTERS SECOND. Flush Use 2537-ST as a 3-1/4" spacer. Install each 2537-ST ush at bottom. Inside View FORT LEFT SIDE WALL LEFT SIDE IMPORTANT! If you have Monkey Bars Install these two 2537-ST balusters rst.

  • Page 42: Rope Ladder

    ROPE LADDER ASSEMBLE & INSTALL 2 x 6 x 84" 2540-ST x2 Pre-assembled Step 1 Feed Ropes up through holes in Upper Rope Arm ( 2540-ST ) and tie a double knot. 21-1/2" Step 2 Slide one Ladder Rung ( 1025-ST ) up the Ropes and tie a single knot in each rope.
  • Page 43 SWINGS INSTALL Clip a Spring Clip at the end of each Swing and Trapeze chain. Then, using the Spring Clips, attach the Swings and Trapeze to the swing brackets on the swing beam, as shown below. 2004 Attach Playset Plaque using One 1"...
  • Page 44 CLIMBING ROPE INSTALL 5/4 x 6 x 84" 2540-ST OPTIONAL: Tie several single knots in locations to allow logical hand-grab points. 2 x 6 x 84" 1088-ST Step 1 Feed top of Climbing Rope through front of Upper Rail ( 2540-ST ) and tie a double knot on the back side ( Fig.
  • Page 45 SLIDE SLIDE MOUNT INSTALL 2" Wood Screw (x2) 1 x 6 x 41-3/4" 1-3/4" 2312-ST 2 x 4 x 22-7/8" 2784-ST 2784-ST 2 x 4 x 15-3/8" Flush Position Slide Mount beneath Deck End Board. Attach with two 2" Wood Screws as shown. Install Part 2784-ST ush to 1001-ST.
  • Page 46 SLIDE MEASURE NOTE: IF SLIDE HAS THREE HOLES, INSTALL 4" FROM FRONT OF DECK. 5/4 x 6 x 66-3/8" 2 x 4 x 22-7/8" 1 x 6 x 41-3/4" 1085-ST 2784-ST 2312-ST Flush 4" Slide SLIDE MEASURE NOTE: IF SLIDE HAS FOUR HOLES, INSTALL 2" FROM FRONT OF DECK. 5/4 x 6 x 66-3/8"...

  • Page 47: Mounting Screws

    SLIDE DRILL NOTE: DEPENDING ON YOUR SLIDE, INSTALL WITH THREE OR FOUR SCREWS. Drill 1/8” holes at dimples through Slide and 2312- into 2784- (1 inch deep). 5/4 x 6 x 41-3/4" 2312-ST Slide SLIDE MOUNTING SCREWS 2-1/2" Pan Head Wood Screw (x3 or x4) 1/4"...

  • Page 48: Safety Handles

    SLIDE SURFACING MATERIAL (not supplied) Apply Surfacing Material at recommended depth, or deeper. Hammer 1015 Ground Stake into ground on either side of slide and attach to slide wall using (2) 1" Screws. 1 x 1-3/8 x 17" 1015 SAFETY HANDLES INSTALL Attach Left and Right Safety Handles to the Step Ladder Rails with two 1/4"...
  • Page 49 STAKES Stakes Flush with TOP. STAKE STAKE STAKE 1015 1 x 1-3/8 x 17" 2-1/2" Wood Screws (x4) STAKE STAKE STAKE Pound in Stakes (1015) at 45 degree angle. Stakes Flush with Make sure all base pieces, uprights and slide SIDES.
  • Page 50 TENT TARP INSTALL End Rail Secure Tent Tarp at Five Areas as shown, equal distance apart on Tent Frame End Rail (1022-ST). BEGIN HERE Install screws through hem for strength. 3/4" Truss Head Screw (x10) 3/16" x 1" Fender Washer (x10) 1-1/2"...
  • Page 51 TENT TARP INSTALL HINT: You may have to roll 1022-ST over to make Tarp taut. Once second 1022-ST is attached, 3/4" Truss Head Screw (x2) + secure tarp THROUGH HEM to top rail. 3/16 x 1" Fender Washer (x2) 2-1/2" Wood Screws (x4) BACK BOTTOM END RAIL GUSSETS INSTALL 3"...
  • Page 52 INSTALL ROPE LADDER BOTTOM SUPPORT GUSSETS 3" Wood Screws 3" Flush Wood Screws at edge. Flush at edge. 1/4" Pre-Drill x 2" deep. 2 x 4 x 18" 3" Wood Screw 1020-ST INSTALL SWING SAFETY BARRIER Pre drill 1/4" x 1-1/2" deep at both sides.

  • Page 53: Steering Wheel

    STEERING WHEEL INSTALL Install 2603 aligned with swing beam inside fort. Flat Washer DO NOT OVER-TIGHTEN LAG BOLT 1-1/2" Lag Bolt Wheel Cap 2603 TELESCOPE INSTALL 1-1/4" Screws Telescope 2073 Telescope Bracket Any Top Rail...
  • Page 54 STOP YOU HAVE FINISHED YOUR BASE PLAYSET. IF YOU HAVE MONKEY BARS PROCEED TO NEXT PAGE. THE TIRE SWING KIT MAY BE INSTALLED NOW. REFER TO THE TIRE SWING INSTALLATION MANUAL.
  • Page 55 INSTALL TOP LADDER SUPPORTS 2 x 4 x 43-1/2" 2322-ST NOTE: Part 2322-ST (43-1/2") is from Monkey Bar Kit. TOP LADDER SUPPORTS INSTALL 2 x 4 x 43-1/2" 2322-ST T-Nut 5" Hex Bolt (x2) Flat Washer Flat Washer T-Nut 5" Hex Bolt T-Nut 8-1/4"...

  • Page 56: 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 57 MONKEY BAR INSTALL - STEP 2 SEE PAGE 8 LEFT SIDE Drill-Through 3/16" marked locations. Re-Drill through using 7/16" 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 58 MONKEY BAR FORT BALUSTERS 5/8 x 3-1/4 x 33" 2537-ST LEFT SIDE Inside View Install 2537-ST ush against board. Install these two 2537-ST balusters rst. Install ush at bottom. 1-1/4" Wood Screws LEFT SIDE 5/8 x 3-1/4 x 33" 2537-ST Inside View Flush Use 2537-ST...
  • Page 59 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 60 Backyard Play Systems does not assume, or authorize any person to assume for us, any other liability in connection with the sale of our products.

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