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Backyard 4158 Manual

Summary of 4158

  • Page 1

    2281 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: customerservi...

  • Page 2

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  • Page 3: Playset

    - before you begin - - before you begin - your premium playset is manufactured from wood which has many natural characteristics and blemishes that may be present in some of the pieces in your playset. These natural characteristics may include knots or mi- nor cracks/splits. All individual parts have...

  • Page 4

    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 ! 2 ‰ wear safety glasses during drilling, assembly of your playset. ‰ children should not be allowed in the play...

  • Page 5: Safety Warnings

    3 safety warnings ‰ this playset has been designed for use by a maximum of eight occupants at one time having a combined weight of 1,200 pounds. (this weight does not include occupants in the sandbox area.) ‰ this playset is recommended for children (3) through (11) years of age. ‰ 2qvlwhdgxowvxshuy...

  • Page 6: 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. Playset checklist at the beginning of each play season: twice a month during play season: once a month during play...

  • Page 7

    2h 2h h l 6 ft. 6 ft. 6 ft. 6 ft. L+6 ft. 6 ft. 6 ft. Use zone for single-axis swings use zone for multi-axis swings denotes use zone with protective surfacing denotes use zone with protective surfacing 5 playground surfacing materials section 4 of the consumer product safety commission’s outdoor ho...

  • Page 8: Orientation

    6 orientation playset *hint* throughout this manual references made to the left side, the right side, the front side and the back side of the playset serve as a consistent reminder to help with assembly. Left side front side back side right side.

  • Page 9: Important!

    A a b b 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 ...

  • Page 10: Wood Parts

    8 w o o d p a r t s l i s t x1 x1 wood parts x1 x2 5/4 x 4 x 45-1/8" x1 x9 x1 x1 3 x 3 x 95" x3 x1 x2 x12 x2 x1 x2 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" 5/4" x 4" ..................................

  • Page 11: Hardware

    Hardware quick clip x6 9 accessories safety handle x3 x3 x1 x6 x1 tent tarp plaque swing climbing rocks climbing rope x1 x4 telescope steering wheel x1 2097 2451 2443 2405 2073 2008-a x6 swing hanger 2194 x1 x1 x1 x1 x2 x1 90 o angle bracket plate swing beam flat plate swing beam angled plate left s...

  • Page 12: X14

    1” 1” 3/8” t - nut 5/16” t - nut 3/8” flat washer 1/4” x 1” fender washer 3/16” x 1” fender washer 3/8” lock washer 5/16” flat washer 5/16” lock washer truss head screw 3/4” 3/8” lock nut 2-1/2” pan head screw 2-1/2” 3/8” 3/8” 3/8” 5/16” 5/16” 1/4” rock wall hardware t - nut lock washer hex bolt fla...

  • Page 13: X30

    3/8” lag bolt woodscrews 4” 2-1/2” 3” 1-1/4” 1-5/8” 2” 3/8” 3/8” 2-1/2” 3/8” 2-1/4” 3/8” 2” 3/8” 3/8” hex head bolts 3-3/4” 1-1/2” 3/8” 1-1/4” 3/8” 1-3/4” 3/8” 6” 3/8” lag bolt 2-1/2” 3/8” lag bolt 3” 11 playset fasteners x30 x4 x4 x2 x2 x6 x125 x62 x85 x38 x5 x8 #2 square drive bit x1 x1 x1 x2.

  • Page 14

    3/8" torque washer 3/8" a c t u a l s i z e s h o w n x4 1-1/2" 3/8” button hd. Screw 3/8” button hd. Screw x2 1-1/4" 5/16" 5/16" x2 3/8" 3-1/2" x2 3/8" 3-3/4" x6 3/8" 6-1/2" x2 3/8" 4-1/2" x2 3/8" 9" x1 12.

  • Page 15: Base Kit

    24'-2" 6' safety area 6' safety area 12'-2" 10'-8" height 12'-6" fr ont side 24'-6" ba ck side l e ft sid e right sid e swing slide ladder r ock w all 24'-2" 6' safety area 6' safety area 12'-2" 10'-8" height front side 33'-6" back side left side right side swing slide ladder monkey bars rock wall 2...

  • Page 16: Begin Playset Assembly

    Begin playset assembly 14 fort corner posts note 2 hole locations. Note 1 hole location. 3" wood screw align braces with pre-drilled holes. Ensure all bracing is square before installing wood screws. Hole for climbing rope bottom flush flush flush t-nut flush x1 x1 2543-w 2503-w 3 x 3 x 95" 3 x 3 x ...

  • Page 17: Fort

    15 fort corner posts x6 fort base align braces with pre-drilled holes. Align braces with pre-drilled holes. Large holes toward top large holes toward bottom flush flip assembly over to install bottom brace flush flush flush 3-3/4" hex bolt lock washer flat washer 3" wood screws flat washer lock wash...

  • Page 18: Fort

    16 fort corner posts x4 note 2 hole location. Note 1 hole location. Align braces with pre-drilled holes. Flush 3" wood screw flush flush flush 3-3/4" hex bolt lock washer flat washer x1 x1 2543-w 2503-w 3 x 3 x 95" 3 x 3 x 95" x1 x1 5/4 x 4 x 45-1/8" 5/4 x 4 x 45-1/8" 2526-st 2501-st fort base align...

  • Page 19: Fort

    17 fort floor frame fort floor frame x6 x16 47" 47" 3-3/4" hex bolt lock washer flat washer t-nut 3" wood screws ensure 47" measurement from erwwrpriedvhwrwrsriÀuvwghfn reinforce bracing with 3" wood screws at all pre-drilled holes. Align braces with pre-drilled holes..

  • Page 20: Fort

    Evenly spaced 18 fort deck cleat 2-1/2" wood screws 1-5/8" wood screws flush flush equal equal equal equal x28 x14 fort deck planks flush 5/4 x 4 x 45-1/8" x1 2516-st x7 2509-st 5/4 x 6 x 45" x4 2-1/2" wood screws.

  • Page 21: Fort

    19 fort deck planks 1-5/8" wood screws fort deck support mark eight (8) holes. 5/4 x 4 x 39" x2 2510-st flush flush flush flush 2 x 4 x 18" x4 1020-st 1020-st flush with outside. X8 x4 2-1/2" wood screws.

  • Page 22: Fort

    20 fort deck support 6((3$*( fort deck support 2-1/2" hex bolt flat washer lock washer do not drill through posts x4 t-nut x4 2 x 4 x 18" x4 1020-st we suggest pre-drilling through deck support using a 1/4" drill bit Àuvwwkhqguloolqjdjdlqxvlqjelw mark and drill 1/4" x 2" deep pre-drill before instal...

  • Page 23: Fort

    21 fort deck support 4" lag bolt lock washer flat washer x4 fort deck rails flush at all corners. Flush at all corners. %rwwrpÁxvkzlwk bottom of deck. X4 x4 3" lag bolt lock washer flat washer x2 5/4 x 4 x 45-1/8" 2501-st 3" wood screws mark and drill 1/4" x 2" deep pre-drill before installing lag b...

  • Page 24: Fort

    22 fort fort swing beam support tent framing t-nut x2 small holes up t-nut x4 6" hex bolt 3-3/4" hex bolt flat washer flat washer lock washer lock washer x2 x4 x2 5/4 x 4 x 71-3/4" 2500-st x1 2505-st 4 x 4 x 45-1/8" set on rail.

  • Page 25: Fort

    23 fort tent framing t-nut 2" hex bolt flat washer lock washer x4 x4 x4 2504-st 5/4 x 4 x 56" pre-drill 1/8" pilot holes 2" deep. Install one 3" wood screw to secure 2504-st’s. 3" wood screw flush at peak step ladder assemble 2-1/2" wood screws x16 back side of ladder x1 2 x 4 x 51" 2 x 4 x 51" x4 5...

  • Page 26: Rock Wall

    1 2 3 4 5 6 7 8 9 place and align planks parallel on a level surface. We recommend a soft surface to protect planks. *hint: number the order of each plank for correct re-orientation, top to bottom. Mark parts on back side or use masking tape. Arrange the rocks in an attractive and practical fashion....

  • Page 27: Rock Wall

    2 2 3 4 5 6 7 8 9 place planks 3 through 9 onto rails, flush to each other. With all planks flush and snug, secure plank 9 only using 4 screws. Maintain dimension shown. - do not attach any other planks at this time. All flush 1 3 2 4 5 6 7 8 9 2 turn all planks over to original position. Align two ...

  • Page 28: Rock Wall

    2 1 1/4" x 1-1/2" hex bolts 1/4" lock washers t-nuts 1/4" flat washers 2 secure remaining planks (3 through 8). Ensure all plank ends are flush, making sure screws install into rails. - do not attach top plank 1 at this time. 2 3 4 5 6 7 8 9 all flush 26 rock wall install 2-1/2" wood screws rock wal...

  • Page 29: Rock Wall

    2 5/16 x 1-1/2" button head screw 5/16" lock washer 5/16"flat washer l-bracket 5/16" t-nut 27 rock wall install rock wall assemble x2 align ladder with inside of post and top of cross brace and mark holes. Flush x2 2412.

  • Page 30: Rock Wall

    28 rock wall install pre-drill two 1/4" pilot holes at marked locations. Re-drill holes from opposite side using 3/8" bit. 6((3$*( back side rock wall rock wall install back side rock wall 5/16" t-nut x2.

  • Page 31: Install

    29 install flush flush 2-1/2" wood screws x4 rock wall x1 5/4 x 4 x 17" 2222-st rock wall install secure middle brace with (2) 2-1/2" wood screws from behind. Flush begin here begin here flush 5/16 x 1-1/4" button head screw 5/16" lock washer 5/16" flat washer x2 2" wood screws x2 x2 2-1/4" pan head...

  • Page 32: Fort Bracing

    30 fort bracing install flat washer flat washer lock washer 3" lag bolt 2-1/4" hex bolt flush flush level level x1 x2 x1 x1 5/4 x 4 x 58-1/2" 5/4 x 4 x 58-1/2" 2538-st 2538-st mark & pre drill 3/16" pilot holes, 2" deep for lag bolts. Angle brace & rock wall install x4 pre drill 3/16" pilot holes, 2...

  • Page 33: Swing Beam

    31 swing beam swing hangers lock nut cap 1-3/8" washer 2 threads min. Use a socket wrench to tighten lock nut securely against washer. Swing hanger bolt must protrude at least two threads beyond lock nut. Swing beam swing hangers - install insert swing hanger and hand-tighten until hanger meets swin...

  • Page 34: Upright

    32 upright install equal equal center 2539-st. Mark and pre drill 7/16" through holes for hex bolt. X1 2539-st 5/4 x 4 x 47" 1-3/4" hex bolt lock washer flat washer x2 t-nut a - frame assemble t-nut x2 3 x 3 x 95" 2525-w rotate 2525-w 180 o after installing t-nuts. 2505-st x2.

  • Page 35: A - Frame

    33 a - frame assemble x1 x2 3-3/4" hex bolt lock washer flat washer 5/4 x 6 x 70-3/4" 2506-st pre-installed t-nuts are underneath. Swing swing beam flat washer lock nut 3-1/2" carriage bolt x2 x2 2411 x1.

  • Page 36: Swing Beam

    34 swing beam install x2 x2 x1 4 x 6 x 95" 2502-st 2448 2447 x1 x1 a - frame install lock nut flat washer x2 2525-w 2499 x1 note: you may need to tap bolts with hammer to get though holes. Clean all debris from bolt threads before installing lock nuts. 4-1/2" carriage bolt 3-3/4" carriage bolt flat ...

  • Page 37: Swing Beam

    35 swing beam install position swing beam assembly resting upon a-frame. Swing a - frame x4 x4 do not fully tighten carriage bolts at this time. Align holes and insert carriage bolt. Repeat where arrows are shown. Note: you may need to tap bolts with hammer to get though holes. Clean all debris from...

  • Page 38: Swing

    36 swing swing beam flat washer lock nut 9" carriage bolt 6-1/2" carriage bolt torque washer x1 x1 x1 x2 2485 x1 swing beam assembly install flat washer lock nut 6-1/2" carriage bolt torque washer you may need to tap with hammer to get though holes. Note: you may need to tap bolts with hammer to get...

  • Page 39: Swing

    37 swing swing swing beam swing beam x1 x1 t-nut 1-1/4" hex bolt lock washer flat washer 2. Re-drill from opposite side using 7/16" bit. 1. Pre-drill using 3/16" bit. 6((3$*(.

  • Page 40: Swing

    38 swing level level swing beam and tighten all swing beam fasteners tighten all fasteners swing a - frame x2 2-1/2" pan head screw 1/4 x 1" fender washer x2 3" lag bolt lock washer flat washer mark and drill 1/4" x 2" deep pre-drill before installing lag bolts..

  • Page 41: Stop

    S p a c e r s p a c e r s p a c e r s p a c e r 2 359 -s t 3-1/4" 3-1/4" 3-1/4" 3-1/4" 3-1/4" 3-1/4" if you have monkey bar option do not install left side balusters yet. If you do not have monkey bar option continue installing all balusters. Stop 39 ,qvwdooÀuvwedooxvwhuv" from upright 2359-st and d...

  • Page 42: Fort

    S p a c e r s p a c e r s p a c e r s p a c e r s p a c e r 3-1/4" 3-1/4" center 3-1/4" 3-1/4" 3-1/4" 3-1/4" s p a c e r 3-1/4" 3-1/4" 1-1/4" 40 &hqwhuÀuvwvsdfhudqglqwdoo edooxvwhuvÁxvkwrghfn 1-1/4" wood screws flush x24 x6 2523-st 5/8 x 3-1/4 x 29-3/4" fort align spacer with inside of srvwdqglqwdoo...

  • Page 43: Roof/canopy

    41 roof/canopy roof/canopy install install 3" wood screws 1-5/8" wood screws flush flush flush flush flush level flush x1 x2 2517-st 2518-st 2 x 4 x 47-1/8" 5/4 x 4 x 47-1/8" x12 x8 x2 5/8 x 3-1/4 x 35-3/4" 2512-st do not over-tighten screws. Keep screw head flush with top of board. 1/8" pre-drill x...

  • Page 44: Roof/canopy

    42 roof/canopy roof/canopy install install 1-5/8" wood screws flush flush flush flush flush x8 1-5/8" wood screws x8 center 2513-st on 2512-st with mark and secure using two 1-5/8" screws. Do not over-tighten screws. Keep screw head flush with top of board. Do not over-tighten screws. Keep screw hea...

  • Page 45: Install

    Fold tarp under tent end rail. Install screws through hem for strength. 3/4" pan head screw (x10) 3/16" x 1" fender washer (x10) end rail 43 install tent tarp x1 2443 x10 3/4" pan head screws pre-drill 1/8" into end grain. 3/4" pan head screw install screws with #3 phillips bit x8 secure canopy to b...

  • Page 46: Swings

    44 swings install 8" minimum when occupied. Adjust chains at top. Attach a quick-clip at the end of each swing and trapeze chain. Then, using the quick-clips, attach the swings and trapeze to the spring clips on the swing beam, as shown below. Attach playset plaque using one 1" philips head screw (p...

  • Page 47: Steering Wheel

    45 steering wheel install 1-1/2" lag bolt flat washer steering wheel cap telescope install telescope telescope bracket any top rail 1-1/4" screws x1 2073 do not over-tighten lag bolts x1 2008-a install on 2008-a on a support inside fort..

  • Page 48: Stakes

    3" 46 stakes make sure all base pieces and uprights duhuhvwlqjÁdwrqwkhjurxqg it may be necessary to loosen the soil beneath playset to make everything level. 3" wood screws x4 3" wood screws x8 install x4 1 x 1-3/8 x 17" 1015 x2 1 x 1-3/8 x 17" 1015 slide surfacing material flush 1-5/16" 2" wood scr...

  • Page 49: Slide

    47 slide locate slide in the opening between balusters on the front side of the tower. Pre-drill 1/8" pilot holes through slide at dimples, through deck planks, and into lower slide support. Ensure screws are installed through deck planks. Move slide slightly to avoid spaces between planks. Front si...

  • Page 50: Safety Handles

    48 safety handles sandbox seats install install x3 2405 1-1/2" lag bolt flat washer x6 do not over-tighten lag bolts 2-1/2" wood screws x8 flush flush x2 5/4 x 6 x 22-1/2" 1120-st.

  • Page 51: Climbing Rope

    49 climbing rope install fig. 1 feed top of climbing rope through front of upper rail ( 2526-st ) and tie a double knot on the back side ( fig. 1) . For safety, insure that the rope is tight enough so that it can not be looped back on itself. Feed lower end of climbing rope through hole in rock wall...

  • Page 52: Stop

    50 if you have monkey bars proceed to next page. Refer to monkey bars instructions for parts. Stop you have finished your base playset..

  • Page 53: Top Ladder Supports

    Top ladder supports install top ladder supports install 51 x2 2 x 4 x 32" 2745-st note: part 2745-st (32") is from monkey bar kit. 5" hex bolt flat washer t-nut t-nut t-nut 5" hex bolt flat washer 3-1/2" hex bolt flat washer lock washer x2 2 x 4 x 32" 2745-st x2 x2.

  • Page 54: Monkey Bar

    Monkey bar monkey bar * use care when installing monkey bar assembly * two people and a step ladder are recommended for this step install position install - step 1 left side 52 left side *hint – clamp monkey bar assembly in place while marking holes. Center monkey bar assembly between corner posts. ...

  • Page 55: Monkey Bar

    Monkey bar install - step 2 monkey bar install - step 3 53 left side left side drill-through 3/16" bit at marked locations. Re-drill through using 7/16" bit from outside of frame at each support hole location. See page 7 see page 7 flush at bottom. Flat washer lock washer 2-1/4" hex bolt x4 t-nut t-...

  • Page 56: Monkey Bar

    Monkey bar stakes 54 s p a c e r s p a c e r s p a c e r s p a c e r s p a c e r 3-1/4” 3-1/4” center 3-1/4” 3-1/4” 3-1/4” 3-1/4” 1-1/4" wood screws &hqwhuÀuvwvsdfhudqglqvwdoo edoxvwhuvÁxvkwrghfn flush x24 x4 install balusters - left side left side 3" wood screws pound in stakes so they are Áxvkdwwr...

  • Page 57: Warranty

    55 warranty backyard play systems warrants the following: 1. All wood and plastic (polymer) coated wood components have a limited lifetime warranty. ‡7uhdwhg:rrg%dfn\dug3od\6\vwhpvzloouhsodfhwuhdwhgzrrgzklfkehfrphvvwuxfwxudoo\xqÀw due solely to damage caused by fungal decay or termites. ‡3odvwlf3ro\...

  • Page 58: Warranty

    56 please feel free to call our consumer help line toll free 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 1rzduudqw\lvriihuhgrqwkhiroorzlqjhtxlsphqwvxemhfwwrdexvhqhjoljhqfh lpsurshulqvwdoodwlrqyd...