PlayNation Play Systems Tahoe Assembly Manual
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PlayNation Play Systems Tahoe Assembly Manual

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Tahoe
ASSEMBLY MANUAL
Copyright © 2009 PlayNation Play Systems, Inc.
All Rights Reserved
Made in the U.S.A.
PlayNation Play Systems, Inc.
190 Etowah Industrial Court
Canton, GA 30114
(800) 661-7295
15/MAY/2009 – Version 2.0.0

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  • Page 1 Tahoe ASSEMBLY MANUAL Copyright © 2009 PlayNation Play Systems, Inc. All Rights Reserved Made in the U.S.A. PlayNation Play Systems, Inc. 190 Etowah Industrial Court Canton, GA 30114 (800) 661-7295 15/MAY/2009 – Version 2.0.0...

  • Page 2: Step 1: Corner Posts

    STEP 1: CORNER POSTS 1: PLACE ONE 2 X 6 X 70" SANDBOX BOARD, OFFSET HOLES UP, FLUSH WITH THE BOTTOM OF TWO 4 X 4 X 96" CORNER POSTS ON THE SIDE WITH ONE THROUGH HOLE. FASTEN THE SANDBOX BOARD TO THE CORNER POSTS WITH 3/8 X 3 1/2" LAG SCREWS AND 3/8" WASHERS. 2: REPEAT THIS PROCESS FOR THE OPPOSITE SIDE.
  • Page 3 STEP 2: BLOCK SUPPORTS 1: INSTALL THE 4 X 4 X 70" BLOCK SUPPORTS TO THE CORNER POSTS AT THE 51-1/2" HOLE. 2: FASTEN THE BLOCK SUPPORTS TO THE CORNER POSTS FROM THE OUTSIDE USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS AND 3/8" WASHERS AND 3/8" LOCK NUTS ON THE INSIDE.
  • Page 4 STEP 3: SANDBOX BOARDS 1: PLACE TWO 2 X 6 X 70" SANDBOX BOARDS, OFFSET HOLES DOWN, FLUSH TO THE BOTTOM OF THE CORNER POSTS. 2: FASTEN THE SANDBOX BOARDS TO THE CORNER POSTS WITH 3/8 X 3-1/2" LAG SCREWS AND 3/8"...

  • Page 5: Step 4: Deck Supports

    STEP 4: DECK SUPPORTS 1: PLACE THE 4 X 4 X 70" DECK SUPPORTS ON TOP OF THE BLOCK SUPPORTS. FASTEN THE DECK SUPPORTS TO THE CORNER POSTS WITH 3/8 X 5" LAG SCREWS AND 3/8" WASHERS FROM THE INSIDE. 2: FASTEN THE DECK SUPPORTS TO THE BLOCK SUPPORTS WITH 3/8 X 5"...
  • Page 6 STEP 5: CENTER POSTS 1: PLACE THE 4 X 4 X 84" CENTER POSTS FLUSH WITH THE BOTTOM OF THE BLOCK SUPPORTS, LINING UP THE PILOT HOLES AT THE CENTER OF THE BLOCK SUPPORTS. 2: FASTEN THE CENTER POSTS TO THE BLOCK SUPPORTS USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8"...

  • Page 7: Lag Screw

    STEP 6: TIRE SWING SUPPORT 1: PLACE THE 4 X 4 X 62-3/4" TIRE SWING SUPPORT FLUSH ON TOP OF THE BLOCK SUPPORTS, IN LINE WITH THE CENTER POSTS. NO SCREWS ARE NEEDED FOR THE TIRE SWING SUPPORT. 2: PLACE THE 2 X 4 X 70" CENTER DECK SUPPORTS FLUSH AGAINST THE CENTER POSTS, ON TOP OF THE BLOCK SUPPORTS.
  • Page 8 STEP 7: BLOCKS AND TIRE SWIVEL 1: PLACE THE 4 X 4 X 25" BLOCKS FLUSH ON TOP OF THE BLOCK SUPPORTS, BETWEEN THE CENTER AND END DECK SUPPORTS. FASTEN THE BLOCKS TO THE BLOCK SUPPORTS WITH 3/8 X 5" LAG SCREWS AND 3/8"...

  • Page 9: Deck Panel

    STEP 8: DECK PANELS 1: PLACE ONE 3-BOARD DECK ON TOP OF THE DECK SUPPORTS, IN FRONT OF EACH OF THE CENTER POSTS, ALLOWING THE 2 X 4 DECK STREAMERS TO OVERLAP THE DECK SUPPORTS. 2: TO THE SIDE OF THE 3-BOARD DECKS, PLACE A 2-BOARD DECK AND SECURE THE DECKS TO THE DECK SUPPORTS WITH 2"...
  • Page 10 STEP 9: END CENTER POSTS 1: PLACE THE 4 X 6 X 38" END CENTER POST AGAINST THE DECK SUPPORTS AND LINE UP THE PILOT HOLES. 2: FROM THE INSIDE, FASTEN THE END CENTER POSTS TO THE DECK SUPPORTS USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS FROM THE OUTSIDE, AND 3/8"...
  • Page 11 STEP 10: CENTER DECK BOARD 1: PLACE THE 5/4 X 6 X 63" CENTER DECK BOARD ACROSS THE TOP OF THE DECK SUPPORTS, BETWEEN THE 2-BOARD DECKS. 2: SECURE THE CENTER DECK BOARD TO THE DECK SUPPORTS WITH 2" WOOD SCREWS. 5/4 X 6 X 63"...

  • Page 12: Step 11: Side Rails

    STEP 11: SIDE RAILS 1: INSTALL THE 4 X 4 X 118" SIDE RAILS TO THE CORNER POSTS AT THE 86" HOLE. FASTEN THE SIDE RAILS FROM THE INSIDE USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" NUTS AND 3/8" WASHERS ON THE OUTSIDE. 2: THE SWING BEAM SIDE RAIL WILL INSTALL IN THE SAME MANNER AS THE SIDE RAIL.
  • Page 13 STEP 12: TRAPEZE ARMS 1: PLACE THE 4 X 6 X 115" TRAPEZE ARM ON TOP OF THE SIDE RAILS FLUSH TO THE REAR CORNER POSTS. WITH A 3/8" DRILL BIT, DRILL A HOLE THROUGH THE 4 X 6 X 115" TRAPEZE ARMS AND THE CORRESPONDING CORNER POSTS.
  • Page 14 STEP 13: LADDER ATTACH THE PRE-ASSEMBLED LADDER TO THE END CENTER AND CORNER POSTS. FASTEN THE LADDER TO THE END CENTER AND CORNER POSTS USING 5" LAG SCREWS AND 3/8" WASHERS FROM THE INSIDE OF THE LADDER RAILS. 5" LAG SCREW 3/8"...

  • Page 15: Back Panel

    STEP 14: PANELS 1: PLACE THE FOUR PRE-ASSEMBLED SIDE PANELS ON TOP OF THE DECK SUPPORT AND CENTER DECK SUPPORT. SEE BELOW FOR DETAILS. ATTACH BOTTOM OF PANEL TO DECK SUPPORTS WITH 2-1/2" WOOD SCREWS. 2: FASTEN TOP OF SIDE PANELS TO THE SIDE TARP SUPPORTS WITH 5" LAG SCREWS AND 3/8" WASHERS.
  • Page 16 STEP 15: ROOF SUPPORTS 1: ATTACH THE 4 X 4 X 76" ROOF SUPPORTS AT THE TOP OF THE CENTER POSTS WITH 3-1/2" LAG SCREWS AND 3/8" WASHERS. THE ANGLED ENDS OF THE ROOF SUPPORTS WILL BE FLUSH TO THE TOP OF THE CENTER POSTS.
  • Page 17 STEP 16: SLIDE PLACE THE SLIDE ON TOP OF THE DECK, OVERLAPPING THE DECK BOARDS. ATTACH THROUGH THE DECK WITH 1-1/4" WOOD SCREWS.
  • Page 18 STEP 17: FILLER BOARD PLACE THE 2 X 6 X 70" FILLER BOARD WITH OFFSET HOLES DOWN FLUSH TO THE TOP OF THE DECK BOARDS. ATTACH TO THE CORNER POSTS WITH 3-1/2" LAG SCREWS AND 3/8" WASHERS. 3-1/2" LAG SCREW 3/8"...
  • Page 19 STEP 18: SWINGS 1: FASTEN THE SWING DUCTILE TO THE BOTTOM OF THE TRAPEZE ARM USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS ON TOP OF THE BEAM, AND 3/8" WASHERS AND NUTS ON THE BOTTOM. 2: HANG THE SWINGS FROM THE IRON DUCTILES USING THE SPRING CLIPS. HANG THE TIRE SWING FROM THE TIRE SWIVEL USING THE SPRING CLIP.
  • Page 20 STEP 19: FORT SUPPORTS 1: PLACE THE 4 X 4 X 16" FORT SUPPORTS WITH COUNTER-SUNK HOLES FACING OUT ON THE CORNER POSTS. THE 45 END SHOULD BE AGAINST THE CORNER POST, AND THE OTHER SHOULD BE LEVEL TO THE TOP OF THE BLOCK SUPPORTS. SEE BELOW FOR CLARIFICATION. 2: FASTEN THE FORT SUPPORTS TO THE BLOCK SUPPORTS WITH 5"...

  • Page 21: Step 20: Safety Boards

    STEP 20: SAFETY BOARDS PLACE THE 2 X 4 X 70" SAFETY BOARD ON THE CORNER POSTS ON THE SIDES WITH SWINGS 30" FROM THE GROUND. ATTACH THE SAFETY BOARDS TO THE CORNER POSTS WITH 3-1/2" LAG SCREWS AND 3/8" WASHERS. 3/8"...
  • Page 22 STEP 21: ROOF 1: FIND ONE 1 X 4 X 74" GROOVE-ONLY ROOF STARTER, AND ONE 1 X 5 X 74" GROOVE-ONLY ROOF STARTER. 2: POSITION THE BOARDS AT THE TOP OF THE ROOF SO THAT THE 1 X 5 ROOF STARTER WILL OVERLAP THE 1 X 4 ROOF STARTER.
  • Page 23 STEP 22: ROOF 1: FIND TWENTY-EIGHT 1 X 6 X 74" TONGUE-IN-GROOVE ROOF BOARDS, TWO 1 X 5 X 74" TONGUE-ONLY ROOF FINISHERS, AND TWO 5/4 X 4 X 69-1/2" ROOF END CAPS. 2: PLACE THE 1 X 6 X 74 ROOF BOARDS ON TOP OF THE ROOF SUPPORTS, FITTING THE TONGUE END INTO THE ROOVE END OF THE ROOF STARTERS.
  • Page 24 STEP 23: ROOF STRINGER 1: FIND TWO 5/4 X 4 X 76" ROOF STRINGERS. 2: CENTER THE ROOF STRINGERS FROM INSIDE THE FORT ON THE ROOF BOARDS. 3: ATTACH THE ROOF STRINGER TO THE ROOF BOARDS WITH 1-1/2" WOOD SCREWS, USING TWO SCREWS PER ROOF BOARD.
  • Page 25 STEP 24: SUNBURST 1: FIND TWO 5/4 X 3 X 53" SUN SUPPORTS. 2: PLACE THE SUN SUPPORTS ON THE OUTSIDE OF THE FORT, AGAINST THE ROOF SUPPORTS AND CENTER UPRIGHT. THE ANGLED ENDS OF THE SUN SUPPORT WILL REST UNDERNEATH THE ROOF BOARDS.
  • Page 26 STEP 25: SUNBURST 1: FIND TWO 2 X 6 X 16" SUNS. 2: PLACE THE SUN ON THE OUTSIDE OF THE SUN SUPPORT, CENTERED TO THE CENTER UPRIGHT. 3: ATTACH THE SUN TO THE SUN SUPPORT WITH 2-1/2" WOOD SCREWS. 2 X 6 X 16"...
  • Page 27 STEP 26: SUNBURST 1: FIND FOUR 5/4 X 2 X 14" LARGE RAYS, AND FOUR 5/4 X 2 X 13" SMALL RAYS. 2: PLACE THE LARGE RAYS BETWEEN THE CENTER UPRIGHT AND SUN AT AN ANGLE THAT ALLOWS THEM TO TOUCH THE ROOF PEAK AND NOT EXTEND PAST THE CENTER OF THE SUN. THE SMALL RAYS WILL INSTALL IN THE SAME MANNER AS THE LARGE RAYS.
  • Page 28 STEP 27: DORMER 1: FIND TWO LEFT SIDE AND TWO RIGHT SIDE DORMER ROOF ASSEMBLIES. 2: FIND TWO DORMER SUNRAY ASSEMBLIES. 3: PLACE THE LEFT AND RIGHT ROOF ASSEMBLIES ON THE BACK SIDE OF THE DORMER SUNRAY ASSEMBLY AS SHOWN BELOW. 4: ATTACH THE DORMER ROOF SIDES TO THE DORMER SUNRAY WITH 1-1/4"...
  • Page 29 STEP 28: DORMER 1: FIND THE DORMER ROOF PEAK ASSEMBLY. 2: PLACE THE ROOF PEAK ASSEMBLY IN THE TOP OF THE ROOF AND FASTEN WITH 1-1/2" WOOD SCREWS. DORMER ROOF PEAK...
  • Page 30 STEP 29: DORMER 1: CENTER THE DORMER ASSEMBLIES ON THE ROOF. 2: USE 2" WOOD SCREWS TO FASTEN THE DORMERS TO THE ROOF. USE 2" WOOD SCREWS IN THESE LOCATIONS (EACH SIDE)
  • Page 31 STEP 30: CHIMNEY 1: FIND THE FRONT AND LEFT SIDE OF THE CHIMNEY. 2: ATTACH THE FRONT AND LEFT SIDES OF THE CHIMNEY WITH A 2" WOOD SCREW. USE A 2" WOOD SCREW IN THIS LOCATION CHIMNEY FRONT CHIMNEY LEFT SIDE 1: FIND THE REAR AND RIGHT SIDE OF THE CHIMNEY.
  • Page 32 STEP 31: CHIMNEY 1: ATTACH THE CHIMNEY SIDES FROM THE PREVIOUS SIDES TO FORM THE CHIMNEY WITH 2" AND 1-1/4" WOOD SCREWS. USE A 2" WOOD SCREW IN THIS LOCATION (EACH SIDE) USE 1-1/4" WOOD SCREWS IN THIS LOCATION (EACH SIDE)
  • Page 33 STEP 32: CHIMNEY 1: FASTEN THE 5/4 X 3 X 6-3/4" CHIMNEY MOUNTING BLOCK TO THE ROOF WITH 1-1/2" WOOD SCREWS. YOU CAN PLACE THE BLOCK AT ANY DESIRED PLACE ON THE ROOF. USE THE DIAGRAM BELOW AS A GUIDE AS TO WHERE YOU MIGHT INSTALL YOUR CHIMNEY.

  • Page 34: Step 33: Steering Wheel

    STEP 33: STEERING WHEEL 1: PLACE THE STEERING WHEEL INSERT INSIDE THE STEERING WHEEL. 2: USE THE HARDWARE INCLUDED WITH THE STEERING WHEEL TO MOUNT THE STEERING WHEEL TO THE 4 X 4 CENTER POST. DO NOT OVER-TIGHTEN THE LAG SCREW INTO THE STEERING WHEEL, OR IT WILL NOT TURN.
  • Page 35 STEP 34: TELESCOPE 1: WITH THE 1-1/4" WOOD SCREWS PROVIDED IN THE TELESCOPE BAG, FASTEN ONE OF THE CIRCLE TELESCOPE BRACKETS ONTO THE SIDE RAIL. 2: PLACE THE TELESCOPE STAND AND TELESCOPE INTO THE SLOT OF THE TELESCOPE BRACKET. 3: FASTEN THE REMAINING TELESCOPE BRACKET TO THE OPPOSITE SIDE THAT THE FIRST TELESCOPE BRACKET WAS INSTALLED ON WITH 1-1/4"...

  • Page 36: Step 35: Safety Handles

    STEP 35: SAFETY HANDLES 1: PLACE THE SAFETY HANDLES ABOVE THE BASE OF THE ENTRY, CENTERED ON THE CORNER POSTS AND THE 4 X 6 CENTER POSTS. 2: ATTACH THE SAFETY HANDLES TO THE CORNER AND CENTER POSTS WITH 1-1/4" PAN HEAD SCREWS.
  • Page 37 STEP 36: FLAG KITS 1: THE TWO FLAG KITS WILL INSTALL ON TOP OF THE SWING BEAMS. 2: USE A 7/8" PADDLE BIT AND DRILL A HOLE AT THE END OF THE TRAPEZE ARM AND ROPE LADDER RUNNER. NO SPECIFIC MEASUREMENT IS NEEDED, BUT THE HOLES SHOULD BE DRILLED ON-CENTER, APROXIMATELY 2"...
  • Page 38 STEP 37: ROPE LADDER RUNNER 1: SWING THE LADDER ASSEMBLY OUT FROM THE FORT. IF THE LADDER ASSEMBLY IS TOO TIGHT, LOOSEN THE LAG SCREWS ENOUGH TO ALLOW THE LADDER TO SWING FREELY. 2: FIND THE 4 X 4 X 74-1/4" ROPE LADDER RUNNER. THE ROPE LADDER RUNNER WILL INSTALL APPROXIMATELY 1"...

  • Page 39: Step 38: Rope Ladder

    STEP 38: ROPE LADDER 1: THREAD THE ROPE THROUGH THE HOLES IN THE ROPE LADDER SUPPORT FROM THE BOTTOM THROUGH THE TOP. FORM A SECURE KNOT AT THE TOP OF THE ROPE LADDER SUPPORT. 2: THREAD THE ROPE THROUGH THE HOLES IN THE ROPE LADDER RUNNER FROM THE FRONT SIDE OF THE ROPE LADDER RUNNER, THROUGH THE BACK SIDE.
  • Page 40 STEP 39: DINNER BELL 1: CENTER THE BASE OF THE DINNER BELL ON THE ROPE LADDER SUPPORT AND ATTACH WITH PROVIDED SCREWS. 2: ASSEMBLE THE BELL AND TIGHTEN TO THE BASE WITH THE PROVIDED NUT...

  • Page 41: Step 40: Swing Beam Plate

    STEP 40: SWING BEAM PLATE 1: PLACE THE SWING BEAM PLATE ON TOP OF THE SWING BEAM SIDE RAIL, LINING UP PILOT HOLES. 2: FASTEN THE SWING BEAM PLATE TO THE SWING BEAM SIDE RAIL ON THE OUTSIDE HOLES USING 3-1/2" CARRIAGE BOLTS WITH 1/2" WASHERS ON TOP, AND 3/8" WASHERS AND 3/8" LOCK NUTS ON THE BOTTOM.

  • Page 42: Angle Bracket

    STEP 41: SWING BEAM 1: BOLT SWING BEAM BLOCK SUPPORTS TOGETHER WITH 6-1/2" CARRIAGE BOLTS AND 1/2" WASHERS THROUGH THE 90 ANGLE BRACKETS. 2: USE 3/8" WASHERS AND 3/8" LOCK NUTS ON BOTTOM SIDE OF BLOCK. 3: USE BOLT CAPS TO COVER ANY EXPOSED THREADS 6-1/2"...
  • Page 43 STEP 42: SWING BEAM 1: PLACE SWING BEAM BLOCK ASSEMBLY ON THE GROUND. 2: PLACE THE 4 X 4 X 120" SWING BEAM LEGS BESIDE THE BEAM BLOCK WITH THE COUNTER-SUNK HOLES FACING OUT. 3: HOLD IN PLACE AND SLIDE 12" CARRIAGE BOLT WITH 1/2" WASHER THROUGH THE 45 ANGLE BRACE, 4 X 4 LEG, SWING BEAM BLOCK ASSEMBLY, 4 X 4 LEG, AND 45 ANGLE BRACE.
  • Page 44 STEP 43: SWING BEAM 1: PLACE SWING BEAM BETWEEN 90 SWING BEAM BRACES. 2: FASTEN THE SWING BEAM TO THE SWING LEGS FROM THE TOP OF THE SWING BEAM USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS. USE 3/8" LOCK NUTS WITH 3/8" WASHERS ON THE 45 ANGLE BRACES. 3: PLACE BOLT CAPS OVER ANY EXPOSED THREADS.
  • Page 45 STEP 44: SWING BEAM 1: LINE UP THE HOLES OF THE IRON DUCTILES WITH THE HOLES IN THE SWINGBEAM. 2: FASTEN THE SWING HANGER TO THE SWING BEAM USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8" WASHERS WITH 3/8" LOCK NUTS. 3: PLACE BOLT CAPS OVER EXPOSED THREADS.
  • Page 46 STEP 45: MOUNT SWING BEAM TO FORT *AN EXTRA PERSON IS REQUIRED FOR THIS STEP 1: PICK UP THE SWING BEAM AND LEG ASSEMBLY. AS YOU LIFT THE BEAM, THE LEGS WILL SCISSOR KEEP CHILDREN AWAY DURING THIS STEP. AS THE LEGS CLOSE, CLOSER TOGETHER.
  • Page 47 STEP 46: SWING BEAM LEGS 1: USE THE SWING BEAM LEGS TO LEVEL THE SWING BEAM. 2: FASTEN THE SWING BEAM LEGS TO THE SWING BLOCK ASSEMBLY WITH 3/8 X 5" LAG SCREWS AND 3/8" WASHERS. 3: TIGHTEN THE 12" CARRIAGE BOLT THAT WAS INSTALLED EARLIER. YOU MAY NEED TO USE LOCKING PLIERS TO HOLD THE CARRIAGE BOLT IN PLACE WHEN INSTALLING.
  • Page 48 STEP 47: SWING BEAM CROSS MEMBER 1: PLACE THE 4 X 4 X 58" SWING LEG CROSS MEMBER ON THE SWING BEAM LEGS AND LEVEL. FASTEN 4 X 4 CROSS MEMBER TO 4 X 4 LEGS WITH 3/8 X 5" LAG SCREWS AND 3/8" WASHERS. 4 X 4 X 58"...

  • Page 49: Step 48: Hanging The Swings

    STEP 48: HANGING THE SWINGS 1: PLACE THE SPRING CLIPS ON THE CHAINS OF THE SWINGS. 2: HANG THE SWINGS BY THE SWING CLIPS FROM THE DUCTILES ON THE SWING BEAM. 3: ADJUST CHAIN HEIGHT AS NECESSARY.

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