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PLAYSTAR Great Escape Safety Manual & Assembly Instructions
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PLAYSTAR Great Escape Safety Manual & Assembly Instructions

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Safety Guide & Assembly Instructions
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PS 8820 PS 8876
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Summary of Contents for PLAYSTAR Great Escape

  • Page 1 ® ® Safety Guide & Assembly Instructions Featured Components (purchase separately): Gold Design Option Shown PS 8820 PS 8876 PS 7690 PS 7956 PS 8850 PS 8840 Featured Components (purchase separately): Featured Components (purchase separately): PS 8816 PS 8860 PS 8820 PS 7952 PS 8876 Featured Components (purchase separately):...
  • Page 2 • Thoroughly read all safety instructions before Testing and Materials (ASTM) Home Playground beginning. Safety Standard. In order for PlayStar to comply with the ASTM Standard, we cannot recommend • Children must remain clear of construction site until anyone above these limits.
  • Page 3 SAFETY INSTALLATION: 2. Only one child, for each single planned 4. Dress children appropriately and do not seat or single planned activity should allow them to wear inappropriate items, 1. Follow the instructions provided, do not be allowed on this set at one time, with such as but not limited to, loose fitting alter its design in any way.
  • Page 4 COMPONENTS INCLUDED (not actual size) Assembly Tool Kit (1) Sturdy Frame Brace (1) TOOLS REQUIRED Level Adjustable Wrench Screwdriver (regular or phillips) Sawhorses (optional) Square Socket Wrench Tape Measure Shovel Pencil Drill Safety Glasses Ladder Hammer HARDWARE INCLUDED (shown actual size) ³...
  • Page 5 BOARDS INCLUDED Before starting to assemble your playset, make sure all boards and hardware are identified and stacked by size. This will 4" improve your assembly time. (35) All boards are identified by “nominal” dimensions. The “actual” width and thickness of boards will vary.
  • Page 6 BOARDS INCLUDED All boards are identified by “nominal” dimensions. The “actual” width and thickness of boards will vary. During assembly process, hide the marked end of the board to the inside so it is not visible on your completed playset. (14) (13) Note:...
  • Page 7 PLEASE NOTE: Letters represent pattern not position Note: When the PlayStar logo is showing, the three tabs on the bottom will position the template square with any two edges. When the arrow is showing, the two tabs on...
  • Page 8 PLEASE NOTE (Letters represent pattern not position) Patterns can be created anywhere along the board by turning the template over (arrow side up) and sliding it to the desired position. Use the shaded holes for that pattern. 1" x 6" 1"...
  • Page 9 ATTACHING CORNER BRACKETS There are several steps in the assembly of your playset when you will be asked to attach “corner brackets”. Please review these diagrams to understand where to place the brackets, how to attach them, and what hardware to use. POSITIONING THE BRACKETS: The “corner bracket”...
  • Page 10 TOWER ASSEMBLY Items for STEP 1: On a flat work surface, lay out two 2" x 4" x 66¹⁄₄" boards 38³⁄₄" apart. Measure and mark both boards at dimensions shown. (2) 2" x 4" x 66¹⁄₄" boards (3) 2" x 4" x 38³⁄₄" boards Attach three 2"...
  • Page 11 Items for STEP 3: 2" x 4" x 58 " (5) ¹ ₂ (5) 2" x 4" x 58¹ ₂" boards (30) #8 x 2¹⁄₂" deck screws PATTERN Stand tower frames on their sides as shown. 59" Attach five 2" x 4" x 58¹⁄₂" boards at dimensions shown.
  • Page 12 Items for STEP 5: (4) 2" x 4" x 28" boards (24) #8 x 2¹⁄₂" deck screws Lift tower assembly upright and position in desired location. Caution: Ground must be level. Installation on a hill or incline will create unsafe conditions. 2"...

  • Page 13: Table Of Contents

    Items for STEP 6: (14) Corner Brackets (56) #8 x 1¹ ₄" deck screws (2) ³ ₈" x 4¹ ₂" hex bolts (12) ³ ₈" x 3¹ ₂" hex bolts (12) ³ ₈" x 2" hex bolts (2) ³ ₈" x 1¹ ₂" lag screws (54) ³...
  • Page 14 Items for STEP 7: (1) 2" x 4" x 38³⁄₄" board (4) #8 x 2¹ ₂" deck screws Predrill the 2" x 4" x 28" boards at the dimension shown. Center the 2" x 4" x 38³⁄₄" board behind the holes and flush with the top. Secure with #8 x 2¹...
  • Page 15 Items for STEP 9: (2) 2" x 4" x 58¹⁄₂" boards (8) #8 x 2¹⁄₂" deck screws Predrill the 2" x 4" x 38³ ₄" boards at the dimension shown. 2" x 4" x 38 ³ ₄ " Center the 2" x 4" x 58¹⁄₂" boards behind the holes and secure with #8 x 2¹...
  • Page 16 Items for STEP 11: Fig. 1 (4) 2" x 4" x 33 ³ ₄" boards (4) 2" x 4" x 24¹ ₄" boards (32) #8 x 2¹⁄₂" deck screws Attach four pre-drilled 2" x 4" x 24¹ ₄" ¹ ₂ "...

  • Page 17: X 1¹ ₄" Deck Screws

    Items for STEP 13: (2) 2" x 4" x 62¹⁄₂" boards (8) #8 x 2¹⁄₂" deck screws PATTERN " Attach two pre-drilled 2" x 4" x 62¹⁄₂" boards as shown. Secure with #8 x 2¹⁄₂" deck screws. 11⁷ ₈" 7 & 8 F AGES ATTERNS Items for STEP 14:...
  • Page 18 Items for STEP 15: (2) 2" x 4" x 44¹ ₄" boards (16) #8 x 2¹ ₂" deck screws " Attach two 2" x 4" x 44¹ ₄" boards 26" at dimensions shown. Secure with #8 x 2¹⁄₂" deck screws. "...
  • Page 19 Items for STEP 17: Caution: Failure to (6) 1" x 4" x 29¹⁄₂" boards pre-drill and counter- (24) #8 x 1¹⁄₂" deck screws sink the boards may result in split lumber. Attach six pre-drilled and counter-sank 1" x 4" x 29¹⁄₂" boards on the outside 1"...
  • Page 20 Items for STEP 19: Attach eight pre-drilled and counter-sank 1" x 4" x 44" and seven pre- drilled and counter-sank 1" x 4" x 29¹⁄₂" boards as shown. The 1" x 4" x (8) 1" x 4" x 44" boards 44"...
  • Page 21 Items for STEP 20: (1) 1" x 6" x 52" - Arched board (2) 1" x 6" x 52" boards (12) #8 x 1¹⁄₂" deck screws Attach one pre-drilled and counter- sank 1" x 6" x 52" - Arched board flush with the top edge of tower as shown.
  • Page 22 Items for STEP 22: Helpful Hint: If you tipped over the tower on it’s side to complete the previous steps. Then (14) 1" x 4" x 29¹⁄₂" boards you may complete first the boards on the (56) #8 x 1¹⁄₂" deck screws 2"...
  • Page 23 Items for STEP 23: (2) 2" x 4" x 58¹⁄₂" boards (2) 2" x 4" x 33³ ₄" boards (16) #8 x 2¹⁄₂" deck screws ₈" Attach two 2" x 4" x 33³ ₄" boards centered in the tower as shown. Secure with ₈"...
  • Page 24 SWING BEAM ASSEMBLY Items for STEP 25: (6) 2" x 4" x 88" boards (48) #8 x 2¹ ₂" deck screws 0" Mark & Drill 3 Boards as shown 13¹ ₄" 13¹ ₄" 25¹ ₂" 12¹ ₄" 37³ ₄" 12¹ ₄" 50"...

  • Page 25: ³ ₈" Lock Nuts

    Items for STEP 26: (3) Step 25 Assemblies (2) Left-hand Sturdy-frame Brackets (1) Right-hand Sturdy-frame Bracket (6) #8 x 1¹ ₄" deck screws (6) ³ ₈" x 3¹ ₂" hex bolts (12) ³ ₈" washers (6) ³ ₈" lock nuts Use the bracket as a drill guide and drill two ¹...
  • Page 26 Items for STEP 27: (2) ³ ₈" x ³ ₄" hex bolts (2) ³ ₈" lock nuts Mate one right-hand bracket assembly to one left-hand bracket assembly as shown. Secure with two ³ ₈" x ³ ₄" hex bolts and ³ ₈" lock nuts through the two lower holes of brackets as shown (do not use flat washers).
  • Page 27 Items for STEP 29: (1) 2" x 4" x 46³⁄₄" board (4) #8 x 2¹⁄₂" deck screws Position assembly as shown. Align the posts so that the outermost points measure 84³⁄₄" as shown. Attach 2" x 4" x 46³⁄₄" board at dimension shown.

  • Page 28: (See Page 9 For Details.)

    Items for STEP 30: (2) corner brackets (8) #8 x 1¹ ₄" screws (2) ³ ₈" x 3¹ ₂" hex bolts (2) ³ ₈" x 2" hex bolts (8) ³ ₈" washers (4) ³ ₈" lock nuts Attach corner brackets. To complete the A-Frame Assembly, flip over as shown and position brackets so that the short side is against the 2"...
  • Page 29 Items for STEP 31: (1) 2" x 6" x 88" board (1) 2" x 6" x 35⁷ ₈" board (4) #8 x 1¹⁄₄" deck screws Lay out the single post assembly and the A-Frame Hold beam tight against bolts installed in Step 28. assembly approximately 92¹...
  • Page 30 Items for STEP 32: (1) 2" x 6" x 88" board (1) 2" x 6" x 35⁷ ₈" board (16) #8 x 2¹ ₂" deck screws Predrill the 2" x 6" x 88" and 2" x 6" x 35⁷ ₈" beam boards at the dimension shown. Attach the drilled 2"...
  • Page 31 Items for STEP 33: Note: If you do not have saw horses, rest beam on ground and rotate A-frame and single (5) ³ ₈" x 3¹ ₂" hex bolts post simultaneously to the other side (10) ³ ₈" washers (requires two adults). Single post must (5) ³...
  • Page 32 Items for STEP 34: Mark the top beam board, on the bottom edge, at the dimensions shown, for swing hanger locations. (6) swing hangers (6) ³ ₈" x 3" lag screws NOTE: If you are installing the Bronco Rider, follow the installation (6) ³...
  • Page 33 CONNECT TOWER AND SWING BEAM Items for STEP 35: On the post of tower assembly where the beam will be attached, measure and mark hole location (7" down and 1⁵ ₈" from edge) as shown. (Fig. 1) (1) ³ ₈" x 4¹ ₂" hex bolt Drill a ³...
  • Page 34 Items for STEP 36: Position 2" x 4" x 28" board 34³ ₄" up from bottom of tower flush with the tower and swing beam posts as shown. Attach with #8 x 2¹ ₂" deck screws. (1) 2" x 4" x 28" board (2) corner brackets Attach corner brackets.
  • Page 35 If you purchased the optional Adventure Tunnel Kit (PS 8876) it must be installed now. Follow the building instructions included with the Adventure Tunnel Kit. Then continue with STOP these Instructions on page 38. If you are not installing the Tunnel Kit, proceed with the instructions below. Items for STEP 37: (2) Corner Brackets (4) #8 x 1¹...
  • Page 36 Items for STEP 38: (2) 2" x 4" x 46³ ₄" boards (4) #8 x 1¹ ₄" deck screws (2) ³ ₈" x 2" hex bolts (4) ³ ₈" washers (2) ³ ₈" lock nuts Attach two 2" x 4" x 46 ³ ₄" boards to corner brackets as shown.
  • Page 37 Items for STEP 40: (12) 1" x 4" x 21⁷⁄₁₆" boards (72) #8 x 1¹ ₂" deck screws Attach twelve 1" x 4" x 21⁷ ₁₆" predrilled and counter-sank boards in between the two boards you attached in the previous step. Start at the top and keep boards tight to each other. Secure with #8 x 1¹⁄₂" deck screws. Do not over tighten the screws.
  • Page 38 10º angle CLIMBING BAR ASSEMBLY Items for STEP 41: On a flat work surface, lay out the 2" x 4" x 88" and 2" x 4" x 46³ ₄" boards as shown. (1) 2" x 4" x 88" board (1) 2" x 4" x 46³ ₄" board Lay bracket flat on the board.
  • Page 39 Items for STEP 42: On a flat work surface, lay out the 2" x 4" x 88" and 2" x 4" x 46³ ₄" boards as shown. (1) 2" x 4" x 88" board (1) 2" x 4" x 46 ³ ₄" board Lay bracket flat on the board.
  • Page 40 Items for STEP 43: Turn Climbing Bar Assembly over. (2) Climbing Bar Assemblies Lay bracket flat on the board. Slide bracket until the stops on the underside (2) Triangle Brackets are tight against the boards as in previous step. (8) #8 x 1¹⁄₄" deck screws (10) ³...
  • Page 41 Items for STEP 44: (8) Climbing Bars (32) #14 x 1¹ ₄" pan head screws Attach Climbing Bars at dimensions shown. 10³ ₄" Use the Climbing Bar as a 21³ ₄" drill guide and drill ¹ ₈" holes 1" deep in the 32³...
  • Page 42 CONNECT TOWER & CLIMBING BAR ASSEMBLY Items for STEP 46: (4) #8 x 1¹⁄₄" deck screws (1) ³⁄₈" x 3¹⁄₂" hex bolt (1) ³⁄₈" x 3" lag screw (3) ³⁄₈" washers (1) ³⁄₈" lock nut Attach Corner Brackets. Lift Climbing Bar Assembly into an upright position at the dimension shown. Dig into the ground about 2"...
  • Page 43 Items for STEP 47: (1) Tarp roof (10) snap screws Align end of tarp (with the five snaps) approximately 1³ ₄" from the bottom edge of the 2" x 4" 58¹ ₂" board and pull outermost edges into position as shown. (Fig.1) Using a pencil, identify and mark each snap location center (should be approximately 2¹...
  • Page 44 STURDY-FRAME BRACE INSTALLATION STEP 48: Remove the top ³⁄₈" x 3¹⁄₂" hex bolt, washers and lock nut from the post support as shown. (Save these parts because they will be used in the next step.) ³⁄₈" x 3¹⁄₂" hex bolt NOTE: It is easiest to remove this bolt by continuing to rotate in a counterclockwise direction.
  • Page 45 ANCHORING Items for STEP 51: At locations shown screw Playset Anchors into ground by hand (a long screwdriver will help). (9) Playset Anchors (9) ³ ₈" x 1¹ ₂" lag screws Use the anchor as a drill guide and drill a ¹⁄₄" hole 1" (9) ³...
  • Page 46 GIANT SCOOP WAVE SLIDE – Mounting Instructions Items for this step: (1) Playset Anchor (2) 2" x 4" x 38³ ₄" boards (24) #8 x 2¹ ₂" deck screws (1) ³ ₈" x 1" hex bolt (2) ³ ₈" washers (1) ³...
  • Page 47 SPIRAL TUBE SLIDE – Mounting Instructions Items for this step: (2) 2" x 4" x 38³ ₄" boards (24) #8 x 2¹ ₂" deck screws Slide two 2" x 4" x 38³ ₄" boards behind the vertical 2" x 4" x 44¹ ₄" boards at dimensions shown.
  • Page 48 Modification for STEP 17: (1) Support Bracket (1) ³ ₈" x 2" hex bolt (1) ⁵ ₁₆" x 1" hex bolt (1) ³ ₈" washer (1) ³ ₈" lock nut Locate the second bolt from the bottom on the Spiral Tube Slide Step 5 Assembly as shown.
  • Page 49 PICNIC TABLE – Mounting Instructions Items for this step: (4) 2" x 6" x 35⁷ ₈" boards (4) Picnic Table Brackets (16) #8 x 1¹ ₄" deck screws (12) ³ ₈" x 1¹ ₂" lag screws 2" x 6" x 35⁷ ₈" (4) (12) ³...
  • Page 50 COMPONENTS – Mounting Instructions SWING SEAT AND GYM RINGS 1. Attach coated ends of chains onto play component using Quick-Link Swing Chain Spacing: Connectors provided. Tighten 10" minimum spacing is Adjustment required from the closest securely with an Adjustable wrench. Zone point of all other rides or stationary objects.
  • Page 51 CLIMBING WALL – Assembly Instructions Align top of Climbing Wall at right angle 90˚). Lip of Climbing Fig. 1 Wall should rest on the play deck 1¹ ₂". Using the Climbing Wall as a template, mark play deck through the three holes in the climbing wall.
  • Page 52 PlayStar, Incorporated, Janesville, WI 53547 © 2009, 2007, PlayStar, Inc. Reproduction of this document in part or whole is prohibited without the permission of PlayStar, Inc. Protected by one or more of the following United States or Foreign Patents: US D418,189; US D409,708; US D424,154; US D428,637; US 6,402,663; US D422,332; US D410,059;...