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PLAYSTAR ADVENTURE TUNNEL Safety Manual & Assembly Instructions
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PLAYSTAR ADVENTURE TUNNEL Safety Manual & Assembly Instructions

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ADVENTURE TUNNEL
Safety Guide & Assembly Instructions
1-888-752-9782
Call Toll Free
We're Here To Help!
PS 8876
Customer Service: Monday - Friday, 8:00 A.M. to 5:00 P.M. C.S.T.

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Summary of Contents for PLAYSTAR ADVENTURE TUNNEL

  • Page 1 ADVENTURE TUNNEL Safety Guide & Assembly Instructions 1-888-752-9782 Call Toll Free We’re Here To Help! PS 8876 Customer Service: Monday - Friday, 8:00 A.M. to 5:00 P.M. C.S.T.
  • Page 2 Testing and Materials (ASTM) Home Playground Testing and Materials (ASTM) Home Playground beginning. beginning. Safety Standard. In order for PlayStar to comply Safety Standard. In order for PlayStar to comply with the ASTM Standard, we cannot recommend with the ASTM Standard, we cannot recommend •...

  • Page 3: Annual Maintenance Checklist

    SAFETY SAFETY INSTALLATION: INSTALLATION: seat or single planned activity should seat or single planned activity should The chains or ropes provided are the The chains or ropes provided are the be allowed on this set at one time, with be allowed on this set at one time, with maximum length designed for the swinging maximum length designed for the swinging a maximum weight of 105 pounds for...

  • Page 4: Tools Required

    COMPONENTS INCLUDED (not actual size) Drill Template (1) Bridge Bracket (2) Tunnel (1) (For RTA only) TOOLS REQUIRED Level Socket Wrench Screwdriver (regular or phillips) Z\," Drill Bit Square Drill Sawhorses (optional) C\," Drill Bit Pencil Saw (for BIY) Shovel Counter-sink Tool Hammer Tape Measure...
  • Page 5 BOARDS INCLUDED Before starting to assemble your playset, make sure all boards and hardware are identified and stacked by size. This will improve your assembly time. 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.
  • Page 6 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 the bottom will position the template square with one edge only, which will allow you to slide the template anywhere along the board.
  • Page 7 PLEASE NOTE (Letters represent pattern not position) B-ALT C-ALT Patterns can be created anywhere along the board by turning the template over (arrow side up) and sliding it 2" x 4" to the desired position. Use the shaded holes for that pattern. 2"...
  • Page 8 For other PlayStar Playsets not listed, of six feet in all directions from the perimeter of the Adventure Call Toll Free at 1-888-752-9782 Tunnel, Rock Walls, Slides, and Climbers. If you are attaching your tunnel kit to a PlayStar STOP Build-It-Yourself ®...
  • Page 9 For other PlayStar Playsets not listed, of six feet in all directions from the perimeter of the Adventure Call Toll Free at 1-888-752-9782 Tunnel, Rock Walls, Slides, and Climbers. If you are attaching your tunnel kit to a PlayStar STOP Ready-To-Assemble ®...
  • Page 10 2" x 4" x 8' — two (2) boards required 75³⁄₄" ADDITIONAL COMPONENTS REQUIRED (purchase separately) (1) Playset Anchors (PS 7690) Follow instructions from page 11 Optional: (1) PlayStar Slide or Climber can be added. See page 42 60" ONLY for deck ADDITIONAL LUMBER REQUIRED (purchase separately) 2"...
  • Page 11 ASSEMBLY Items for STEP 1: Supplied with Kit: 2" x 4" x 28" board 2" x 4" x 31Z\x" board 2" x 4" x 58Z\x" board (12) #8 x 2Z\x" deck screws 28" 29⁷⁄₈" Purchase Separately: 2" x 4" x 75C\v" board for 48"...
  • Page 12 28" 90º 90º 90º Items for STEP 3: 31¹⁄₂" Supplied with Kit: 2" x 4" x 28" board 29⁷⁄₈" 2" x 4" x 31Z\x" board 2" x 4" x 58Z\x" board (12) #8 x 2Z\x" deck screws 90º C-ALT Purchase Separately: 2"...
  • Page 13 Items for STEP 5: STEP 2 assembly STEP 4 assembly 2" x 4" x 21Z\x" boards Stand left and right side assemblies up as shown 2" x 4" x 58Z\x" board approximately 21Z\x" apart. (12) #8 x 2Z\x" deck screws Pre-drill the 2"...
  • Page 14 Items for STEP 6: (18) 1" x 4" x 21M\zn" boards (108) #8 x 1Z\x" deck screws Attach eighteen pre-drilled and counter-sank 1" x 4" x 21M\zn" boards. Flush Attach the front and back boards flush with the 2" x 4" x 21Z\x" boards and equally space the remaining boards.
  • Page 15 Items for STEP 8: 2" x 6" x 21Z\x" arched board #8 x 2Z\x" deck screws Tight Pre-drill both 2" x 4" x 32Z\x" boards at the dimension shown. Flush " 2" x 6" x 21¹⁄₂ Arched Attach the 2" x 6" x 21Z\x" arched board tight at the top with the 2"...
  • Page 16 Items for STEP 10: 2" x 4" x 21Z\x" boards #8 x 2Z\x" deck screws Note: For this board, use one of the two extra 2" x 4" x 31Z\x" boards supplied with your tunnel kit and cut it down to 21Z\x". Attach the 2"...
  • Page 17 STEP 12-A: STEP 12-B: Identify your Playset’s opening where tunnel Identify your Playset’s opening where tunnel kit is to be attached. It should look like either kit is to be attached. It should look like either STEP 12-A or STEP 12-B. STEP 12-A or STEP 12-B.
  • Page 18 Items for STEP 13: Bring the Bridge-Tunnel to its final position as shown. Make sure the bridge-tunnel decking is level. Bridge-tunnel assembly #8 x 2Z\x" deck screws Anchors Attach Bridge-tunnel assembly to tower as shown. Make sure its decking frame firmly rests against the tower decking frame without any gap in between.
  • Page 19 Items for STEP 14: 2" x 6" x 28" arched board #8 x 2Z\x" deck screws Attach the 2" x 6" x 28" arched board at the dimensions shown. Make sure the arch is centered with the opening. Secure with #8 x 2Z\x" deck screws. Note: Depending on your playset model, some additional adjusting may be necessary in order to get...
  • Page 20 Items for STEP 16: Tunnel (36) #8 x B\," truss head screws Position the tunnel into the bridge opening as shown. Make sure the tunnel is fully inserted and the flanges are firmly resting against the lumber and the ends are flush with the sides of the lumber as shown.
  • Page 21 Items for STEP 17: Bring the Bridge-Tunnel to its final position as shown. Make sure the bridge-tunnel decking is level. Bridge-tunnel assembly #8 x 2Z\x" deck screws Attach Bridge-tunnel assembly to tower as shown. Make sure the Anchors bridge decking is centered with the tower decking. Also, make sure the top surfaces of both decks are flush as shown.
  • Page 22 Items for STEP 18: 2" x 6" x 28" arched board #8 x 2Z\x" deck screws 2" x 6" x 28" Arched Attach the 2" x 6" x 28" arched board centered in opening at the dimensions shown. Make sure the arch is centered with the opening.
  • Page 23 Items for STEP 20: Center Tunnel (36) #8 x C\v" truss head screws Flush Position the tunnel into the bridge opening as shown. Make sure the tunnel is fully inserted and the flanges are Start with firmly resting against the lumber this hole and the ends are flush with the sides of the lumber as shown.
  • Page 24 READY TO ASSEMBLE ® Items for STEP 1: 2" x 4" x 28" board 28" 2" x 4" x 31Z\x" boards 90º 2" x 4" x 58Z\x" board (12) #8 x 2Z\x" deck screws 90º 90º On a flat work surface, lay out one 2"...
  • Page 25 STEP 3: Flip tower side frame over as shown. Using one of the bridge brackets as template, locate both edges of the bracket flush with edges of the 2" x 4" x 58Z\x" as shown. Mark the two large holes at the top of the bracket. Drill using a C\," drill bit at the marked locations.
  • Page 26 Items for STEP 5: Attach three pre-drilled and counter-sank 1" x 4" x 29Z\x" boards at dimensions shown. Equally space boards. Secure with #8 x 1Z\x" deck 1" x 4" x 29Z\x" boards screws. Do not over tighten the screws. (12) #8 x 1Z\x"...
  • Page 27 Items for STEP 7: Stand left and right side assemblies up as shown approxi- mately 21Z\x" apart. STEP 3 assembly STEP 6 assembly Pre-drill the 2" x 4" x 21Z\x" boards at the dimension shown. 2" x 4" x 21Z\x" boards 2"...
  • Page 28 Items for STEP 9: Attach one 2" x 4" x 24Z\v" board flush with 2" x 4" x 24Z\v" board the top and sides as shown. Secure with #8 x 2Z\x" deck screws #8 x 2Z\x" deck screws. " 5³⁄₄ Flush SEE PAGES 6 AND 7 FOR HOLE PATTERNS...
  • Page 29 #8 x 2Z\x" deck screws. SEE PAGES 6 AND 7 FOR HOLE PATTERNS If you are attaching this Tunnel kit to an existing PlayStar RTA Playset, skip to Step 15. STOP Items for STEP 12: Follow this section only if you are attaching this Tunnel kit during initial construction of 1"...
  • Page 30 Items for STEP 13: Center the 2" x 4" x 46C\v" board behind and flush with the top 1" x 4" x 21M\zn" board as shown. Secure with 2" x 4" x 46C\v" board #8 x 1Z\x" deck screws. Do not over tighten the screws. #8 x 1Z\x"...
  • Page 31 STEP 15: Note: If you are attaching this Tunnel kit to an existing PlayStar RTA playset remove the rock wall and the hardware that attaches it from the playset. Save the hardware for later use. Put rock wall assembly on its side as shown.
  • Page 32 Items for STEP 17: Rock wall assembly C\," x 2" hex bolts C\," washers C\," lock nuts Position rock wall as shown, making sure the C\," holes line up with the holes previously drilled. Secure bridge brackets with C\," x 2" hex bolts, C\,"...
  • Page 33 STEP 19-A: STEP 19-B: Identify your Playset’s opening where tunnel kit is to Identify your Playset’s opening where tunnel be attached. It should look like either STEP 19-A or kit is to be attached. It should look like either STEP 19-B. STEP 19-A or STEP 19-B.
  • Page 34 Items for STEP 20: Bring the Bridge-Tunnel to its final position as shown. Note: ONLY FOR a PRE-EXISTNG rock wall with 2" x 4" x 50 C\v" STEP 18 assembly instead of 2" x 4" x 46 C\v" frame boards; remove the bottom #8 x 2Z\x"...
  • Page 35 Items for STEP 21: 2" x 6" x 28" arched board #8 x 2Z\x" deck screws Attach the 2" x 6" x 28" arched board at the dimensions shown. Make sure the arch is centered with the opening. Secure with #8 x 2Z\x"...
  • Page 36 Items for STEP 23: Tunnel (36) #8 x B\," truss head screws Position the tunnel into the bridge opening as shown. Make sure the tunnel is fully inserted and the flanges are firmly resting against the lumber and the ends are flush with the sides of the lumber as shown.
  • Page 37 Items for STEP 24: Bring the Bridge-Tunnel to its final position as shown. Note: ONLY FOR a PRE-EXISTNG rock wall with 2" x 4" x 50 C\v" STEP 18 assembly instead of 2" x 4" x 46 C\v" frame boards; remove the bottom 1" x 4" #8 x 2Z\x"...
  • Page 38 Items for STEP 25: 2" x 6" x 28" arched board #8 x 2Z\x" deck screws 2" x 6" x 28" Arched Attach the 2" x 6" x 28" arched board centered in opening at the dimensions shown. Make sure the arch is centered with the opening.
  • Page 39 Items for STEP 27: 2" x 4" x 19" board #8 X 2Z\x" deck screws Attach one 2" x 4" x 19" board tight with the 2" x 6" x 28" arched and flush with the side of the opening as shown. Secure with #8 X 2Z\x"...
  • Page 40 Items for STEP 28: Position the tunnel into the bridge opening as shown. Tunnel Make sure the tunnel is fully inserted and the flanges are (36) #8 x C\v" truss head screws firmly resting against the lumber and the ends are flush with the sides of the lumber as shown.
  • Page 41 COMPONENTS – Mounting Instructions Refer to your original PlayStar Slide or Climber instructions for complete installation details. ANCHORS At the base of the tunnel, screw Playset Anchors into ground by hand (a long screwdriver will help). Use the anchor as a drill guide and drill a Z\v" hole 1" deep into the board.
  • Page 42 ACTIVITY OPTION - LEFT 1. Remove three 1" x 4" x 29Z\v" boards from the left side of the tunnel exit. 2. Add any of these accessories • Climbing Wall (PS 8850) • Climbing Steps (8860) • Slides (PS 8813 and PS 8814) •...
  • Page 43 Playset Modifications ® TRAINER - GOLD Items for Climbing Step Replacement: Additional Materials Required (Purchase Separately) – 5/4" x 6" x 8' – One board required (2) B\v" x 6" x 36C\v" boards (cut from lumber listed above) (3) B\v" x 6" x 9" boards (cut from removed panels) (20) #8 x 2Z\x"...
  • Page 44 RIDGELINE - BRONZE TRAINER - BRONZE & STARTER Vertical Climber Replacement: Vertical Climber Replacement: Before tunnel installation, relocate this board down Before tunnel installation, relocate this board down so bottom edge is 27Z\x" above deck surface. so bottom edge is 27Z\x" above deck surface. 27Z\x"...
  • Page 45 CONTENDER - SILVER Items for Climbing Wall Replacement: Additional Materials Required (Purchase Separately) – 5/4" x 6" x 10' – One board required (3) B\v" x 6" x 36C\v" boards (cut from lumber listed above) (3) B\v" x 6" x 9" boards (cut from removed panels) (24) #8 x 2Z\x"...
  • Page 46 RIDGELINE - GOLD — LEGACY - GOLD Items for Climbing Steps Replacement: Additional Materials Required (Purchase Separately) – 5/4" x 6" x 8' – One board required – (12) #8 x 2-1/2" deck screws (1) 2" x 4" x 12Z|v" board (cut from 2" x 4" x 19" supplied with Tunnel Kit) (1) 2"...
  • Page 47 LEGACY - BRONZE Items for Climbing Step Replacement: Additional Materials Required (Purchase Separately) – 5/4" x 6" x 10' – One board required (3) B\v" x 6" x 36C\v" boards (cut from lumber listed above) (3) B\v" x 6" x 9" boards (cut from removed panels) (24) #8 x 2Z\x"...
  • Page 48 SUPER STAR - GOLD Items for Scoop Wave Slide Replacement: Additional Materials Required (Purchase Separately) – 5/4" x 6" x 8' – One board required (2) B\v" x 6" x 32Z\x" boards (cut from lumber listed above) (8) #8 x 2Z\x" deck screws (reused from removed panels) Scoop Wave Slide Replacement: Before tunnel installation, first remove two B\v"...
  • Page 49 SUPER STAR - SILVER Items for Scoop Wave Slide Replacement: Additional Materials Required (Purchase Separately) – 5/4" x 6" x 8' – One board required (2) B\v" x 6" x 32Z\x" boards (cut from lumber listed above) (8) #8 x 2Z\x" deck screws (reused from removed panels) Scoop Wave Slide Replacement: Before tunnel installation, first remove two B\v"...
  • Page 50 SUPER STAR - SILVER Items for Giant Scoop Wave Slide Replacement: Additional Materials Required (Purchase Separately) – 5/4" x 6" x 8' – One board required (2) B\v" x 6" x 33Z\v" boards (cut from lumber listed above) (8) #8 x 2Z\x" deck screws (reused from removed panels) Giant Scoop Wave Slide Replacement: "B"...
  • Page 51 Playset Modifications ® GREAT ESCAPE - GOLD, SILVER, BRONZE, & STARTER SUMMIT - GOLD, SILVER, BRONZE Before Tunnel installation, remove Climbing Rock Wall and connecting corner brackets. ALL PRO - GOLD, SILVER, BRONZE, & STARTER Before Tunnel installation, remove Climbing Rock Wall and connecting corner brackets.
  • Page 52 ( 7 5 2 - 97 82 ) Thank you for choosing PlayStar. © 2020, 2014, 2009 PlayStar, Inc. Reproduction of this document in part or whole is prohibited without the permission of PlayStar, Inc. PlayStar, Incorporated, Janesville, WI 53547 Protected by one or more of the following United States or Foreign Patents: US D418,189;...

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