Backyard Discovery CABANA 2004511 Assembly instructions

Made in China | INS-2004511, 2004535, 2004566, 2004559, 2004542, 2004528-A-CABANA-ENG 4/21/20
For the most up to date assembly manual,
to register your set, or to order replacement parts please visit
www.backyarddiscovery.com
SAVE THIS ASSEMBLY MANUAL FOR FUTURE REFERENCE IN THE EVENT THAT
YOU NEED TO ORDER REPLACEMENT PARTS.
Model # 2004511, 2004535,
2004542, 2004559,
2004528, 2004566
CABANA
Owner's Manual & Assembly Instructions
MANUFACTURED BY:
Backyard Discovery
3305 Airport Drive
Pittsburg, KS 66762
800-856-4445
average 2 person assembly time
assembly time may vary based on skill level
2004511 FIRESIDE CABANA
(BAMBOO - CAST SLATE)
2004535 FIRESIDE CABANA
(BAMBOO - SPECTRUM INDIGO)
2004566 HAVEN CABANA PERGOLA
(BAMBOO PATTERN)
2004542 FIRESIDE CABANA
(PEBBLE - SPECTRUM INDIGO)
2004559 FIRESIDE CABANA
(PEBBLE - CAST SLATE)
2004528 HAVEN CABANA PERGOLA
(PEBBLE PATTERN)
TO

The store where you made your purchase
does not stock parts for this item.
If you have assembly questions or you are missing or
have damaged parts, please call
MISSING A PART?
CALL US BEFORE GOING
BACK TO THE STORE
you can also visit www.backyarddiscovery.com
or e-mail [e-mail]
Please have the following information ready when you make your call:
• Model Number of the product located on the front of the assembly manual
• The item description and number from the parts list from the manual that was included in your box
1-800-856-4445
• Read entire assembly manual, paying special attention to the important tips and safety information.
• To ensure there are no missing pieces do a complete inventory by rst separating and identifying all parts.
• Make sure to check packing material for small parts that may have fallen out during shipment.
• Structures are not intended for public use. The Company does not warranty any of its residential structures
subjected to commercial use.
• This manual contains helpful information concerning assembly preparation, installation procedure and
required maintenance.
• Always keep safety in mind as your structure is being built.
• Keep these instructions for future reference.
Please Read This Before Starting Assembly
Owner’s Manual
2

3
Tracking Number Reference Label
Tracking ID number on the carton and on the bottom of the vertical ID plate are included for tracking purposes associated with warranty claims.
This Limited Warranty by Backyard Discovery applies to products manufactured under the Backyard Discovery brand or its other brands
including but not limited to Backyard Botanical, Adventure Playsets, and Leisure Time Products.
Backyard Discovery warrants that this product is free from defect in materials and workmanship for a period of one (1) year from the
original date of purchase. This one (1) year warranty covers all parts including wood, hardware, and accessories. In addition, all cabana
products carry a five (5) year limited warranty, all wood carries a five (5) year limited warranty on rot and decay. Refer to warranty
limitations associated with replacement of parts under this Limited Warranty. In addition, Backyard Discovery will replace any parts within
the first 30 days from date of purchase found to be missing from or damaged in the original packaging
This warranty applies to the original owner and registrant and is non-transferable. Regular maintenance is required to assure maximum life
and performance of this product. Failure by the owner to maintain the product according to the maintenance requirements may void this
warranty. Maintenance guidelines are provided in the Owner’s Manual.
This Limited Warranty does not cover:
Please read entire booklet completely before beginning the assembly process
Please retain these instructions and your receipt for future reference. Keep them in a safe place where you can refer to them as needed.
In order to provide you with the most effecient service, it is required that you provide us with the part numbers when ordering parts.
For Your Records:
Please take time and fill out the information below. This information will be needed for warranty issues.
Where Purchased:
Date of Purchase:
Installation Date:
Installed by:
Tracking Number:
Owner’s Manual Limited Warranty
Backyard Discovery products have been designed for safety and quality. Any modifications made to the original product could damage the
structural integrity of the unit leading to failure and possible injury. Modification voids any and all warranties and Backyard Discovery
assumes no liability for any modified products or consequences resulting from failure of a modified product.
This product is warranted for RESIDENTIAL USE ONLY. Any unintended use such as home child care, daycare center, faith center,
government facility, home owner's associate, park or school will make the warranty of our product null & void.
•Labor for any inspection
•Labor for replacement of any defective item(s)
•Incidental or consequential damages
•Cosmetic defects which do not affect performance or integrity of a part or the entire product
•Vandalism, improper use, failure due to loading or use beyond the capacities stated in the applicable Assembly Manual.
•Acts of nature including but not limited to wind, storms, hail, floods, excessive water exposure
•Improper installation including but not limited to installation on uneven, unleveled, or soft ground
•Minor twisting, warping, checking, or any other natural occurring properties of wood that do not affect performance or integrity

WARNING
• DO NOT climb or walk on the roof for any reason
• Requires two or more people to assemble safely
• Check for underground utilities before digging or
driving stakes into the ground.
• Check carefully for overhead lines and ensure there is
at least 6ft (2m) clearance from any overhead electrical
wires.
• Permanent structures may require a building permit.
As the purchaser and or installer of this product you are
advised to consult local planning, zoning and building
inspection departments for guidance on applicable
building codes and/or zoning requirements.
• Wood is NOT ame retardant and will burn. Grills, re pits
and chimineas are a re hazard if place too close to your
structure.
• Wear gloves to avoid injury during installation.
• During installation, follow all safety warnings provided
with your tools and use safety glasses.
• Check all nuts and bolts twice monthly during the usage
season and tighten as required.(But not so tight that you
crack the wood) It is particularly important that this
procedure be followed at the beginning of each season.
• Oil all metallic moving parts monthly during the usage
period.
• Check all coverings for bolts and sharp edges twice
monthly during usage season to be certain they are in
place. Replace when necessary. It is especially important
to do this at the beginning of each new season.
• For rusted areas on metallic members such as hinges,
brackets, etc. sand and repaint, using a non lead-based
paint meeting the requirements of Title 16 CRF Part 1303.
• Inspect wood parts monthly. The grain of the wood
sometimes will lift in the dry season causing splinters to
appear. Light sanding may be necessary to maintain a
safe environment. Treating your Product with protection
(sealant) after sanding will help prevent severe checking/
splitting and other weather damage.
• We have applied a waterborne translucent stain to your
unit. This is done for color only. Once or twice a year,
depending on your climate conditions, you must apply
some type of protection (sealant) to the wood of your unit.
Prior to the application of sealant, lightly sand any“rough”
spots on your set. Please note this is a requirement of
your warranty.
OWNERS SHALL BE RESPONSIBLE FOR MAINTAINING THE LEGIBILITY OF THE WARNING LABELS
IT IS IMPORTANT TO CHECK AND TIGHTEN ALL HARDWARE AT THE BEGINNING AND DURING
THE SEASON AS THEY MAY LOOSEN DUE TO WOOD EXPANSION AND CONTRACTION.
Owner’s Manual Safety Warnings and Maintenance Instructions
4

About Our Wood
Backyard Discovery uses 100% Cedar (C. Lanceolata) wood. Although we take great care in
selecting the best quality lumber available, wood is still a product of nature and susceptible
to weathering which can change the appearance of your set.
Your Backyard Discovery structure is designed and constructed of quality
materials. As with all outdoor products it will weather and wear. To maximize
the enjoyment, safety and life of your structure it is important that you properly
maintain it.
What causes weathering? Does it aect
the strength of my product?
One of the main reasons for weathering is the
eects of water (moisture); the moisture content
of the wood at the surface is dierent than the
interior of the wood. As the climate changes,
moisture moves in or out of the wood, causing
tension which can result in checking and or
warping. You can expect the following due to
weathering. These changes will not aect the
strength of the product:
1. Checking is surface cracks in the wood along
the grain. A post (4”x 4”) will experience more
checking than a board (1”x 4”) because the surface
and interior moisture content will vary more widely
than in thinner wood.
2. Warping results from any distortion (twisting,
cupping) from the original plane of the board and
often happens from rapid wetting and drying of
the wood.
3. Fading happens as a natural change in the
wood color as it is exposed to sun-light and will
turn grey over time.
How can I reduce the amount of
weathering to wood product?
1. Your wood product is coated with a
water-based stain.Sunlight will break down
the coating, so we recommend applying
a water repellent or stain on a yearly basis
(see your local stain and paint supplier for a
recommended product). You must apply some
type of protection (sealant) to the wood of your
product. Please note this is a requirement
of your warranty. Most weathering is just
the normal result of nature and will not aect
safety. However if you are concerned that a part
has experienced a severe weathering problem
please call our customer service department for
further assistance.
2. Inspect wood parts monthly. The grain of
the wood sometimes will lift in the dry season
causing splinters to appear. Light sanding may
be necessary to maintain a safe environment.
Treating your Product with protection (sealant)
after sanding will help prevent severe checking/
splitting and other weather damage.
Instructions for Proper Maintenance
Owner’s Manual
5

Protrusion Hazard
Proper Hardware Assembly
1/8”
CorrectIncorrect
If you see exposed threads
and your bolt protrudes
beyond the T-Nut you
may have over tightened
the bolt. To eliminate this,
remove the bolt and add
washers to eliminate the
problem.
Bolt and Barrel Nut Assembly
Insert barrel nut through the lock washer and press the pair
through the provided hole. Insert your bolt through the second
lock washer and insert the pair into the provided hole opposite
from the barrel nut. Turn clockwise to thread into the barrel nut.
Do not completely tighten until instructed. LOCK WASHER
BARREL NUT
LOCK WASHER
BOLT
Bolt and T-Nut Assembly
Tap T-nut into the provided hole. Insert your bolt through the
lock washer and insert into the provided hole opposite from the
T-Nut. Turn clockwise to thread into T-nut. Do not completely
tighten until instructed.
T-NUT
LOCK WASHER
BOLT
Lag Assembly
Normally there will be a pre-drilled pilot hole on assemblies
that require a Lag Screw. If there is no pilot hole, line up the two
boards as they are to be attached and use the factory drilled hole
as a guide to drill another pilot hole into the adjoining board.
is will keep the wood from splitting. Only a lock washer is
required for steps with Lag Screws. LOCK WASHER
LAG SCREW
Owner’s Manual Assembly Tips
6

Hardware Identication
Hardware bags are printed with
a seven digit alpha-numeric part
number. During assembly you only
need to reference the last three
digits of the part number as noted
in each step. This will make nding
the correct hardware easier.
BOLT WH
5/16 x 1-3/4 - H100378
378
(x2)
ASSEMBLY TIP:
Keep an eye out for these boxes which will contain helpful pictures and information making
the assembly process as quick and painless as possible.
Sorting Wood
Sorting Hardware
When removing the wood from the boxes we recommend arranging them by part number before you begin
assembly. This will allow for faster assembly and easily identify any parts that may be missing or damaged.
To help with assembly we recommend sorting your hardware bags with the seven digit alpha-numeric number
printed on the bags or by hardware type (i.e. bolts, nuts, etc.). Organizing your hardware will make assembly easier.
NUT BARREL
H100545
SCREW
H100695
T-NUT
H100699
WASHER FLAT
H100706
BOLT HEX
H100716
BOLT
H100718
SCREW PWH
H100742
G2
G1
F2
F1
E1
E2
192(x2)
199(x2)
198(x2)
378(x2)
Assembly Tips
Owner’s Manual
7

Owner's Manual Tools Required for Installation
8

It is critically important that you start with square and level footings, concrete pad or deck to
attach your structure
•Pay close attention to the items needed for each step. Make sure you are using the correct hardware for each step.
Using incorrect hardware may result in improper assembly
•Remember to double check for underground utilities and overhead electrical lines
Owner's Manual Basic Setup Dimensions & Assembly Notes
Post mounts are provided with your structure which allows you to permanently install your structure to a
pre-existing or new wood or concrete surface.
•The hardware to attach the post mounts to the structure is included.
•The hardware to mount the structure permanently to a concrete surface is included.
•The hardware to mount the structure permanently to a wood deck is NOT included and will need to be purchased
separately. You must ensure there is ample structural support under the deck before permanently attaching.
7'-4 1/4"
[2.2 m]
10'-4 7/8"
[3.2 m]
9'-10 1/2"
[3 m]
2'- 1/2"
[.6 m]
ARM REST
1'-6 1/8"
[.5 m]
CUSHION
1'-7/8"
[.3 m]
FRAME
2'-7/8"
[.7 m]
TABLE
8'- 3/4"
[2.5 m]
7'-6 1/4"
[2.3 m]
13'-3 1/4"
[4 m]
NOTE:
DISREGARD SEATING DIMENSIONS
FOR MODELS 2004528 AND 2004566
9

BEFOREYOUBEGINTHEASSEMBLYOFYOURBACKYARDDISCOVERYCABANAPERGOLAPLEASEUSETHETABLEBELOWTO
ENSUREYOURECEIVEDALLCOMPONENTSNEEDEDFORTHEITEM#YOUPURCHASED.IFYOUAREMISSINGANYCARTONS
PLEASECONTACTOURCUSTOMERSERVICETEAMAT1‐800‐856‐5424.
10

Owner's Manual
Wood Components (Not to Scale
9205338 - Parts Identification
LOWER SUPPORT - W4L13032
1 3/8"x4 3/8"x81 1/4" (36x112x2065)
AN1
(1)
TOP SUPPORT - W4L13069
1 3/8"x4 3/8"x81 1/4" (36x112x2065)
AN2
(2)
LOWER SUPPORT - W4L13070
1 3/8"x4 3/8"x81 1/4" (36x112x2065)
AN3
(1)
BEAM - W4L12941
1 3/8"x5 1/4"x111 1/4" (36x134x2826)
D1
(1)
BEAM - W4L12942
1 3/8"x5 1/4"x111 1/4" (36x134x2826)
D2
(1)
BEAM - W4L12943
1 3/8"x5 1/4"x124 7/8" (36x134x3172)
D3
(1)
BEAM - W4L12944
1 3/8"x5 1/4"x146 1/4" (36x134x3714)
D4
(1)
SUPPORT BRACE - W4L13037
1 3/8"x5 1/4"x7 7/8" (36x134x199)
D6
(2)
TOP JOIST - W4L12945
1 3/8"x3 3/8"x82 1/4" (36x86x2091)
E1
(2)
TOP JOIST - W4L12946
1 3/8"x3 3/8"x72 1/8" (36x86x1832)
E2
(2) TOP JOIST - W4L12947
1 3/8"x3 3/8"x61 7/8" (36x86x1572)
E3
(2)
TOP JOIST - W4L12948
1 3/8"x3 3/8"x51 5/8" (36x86x1310)
E4
(2)
TOP JOIST - W4L12949
1 3/8"x3 3/8"x41 1/4" (36x86x1048)
E5
(2)
TOP JOIST - W4L13031
1 3/8"x3 3/8"x31" (36x86x786)
E6
(2)
LOWER SUPPORT - W4L13034
1"x3 3/8"x53 7/8" (24x86x1368)
H1
(8)
11

Owner's Manual
Wood Components (Not to Scale)
9205338 - Parts Identification
LOWER SUPPORT - W4L12940
1"x4 3/8"x81 1/4" (24x112x2065)
Q1
(4)
POST - W2A02915
7"x7"x89 1/2" (178x178x2274)
PT1
(1)
POST - W2A02917
7"x7"x89 1/2" (178x178x2274)
PT3
(1)
PT2 POST - W2A02916
(1) 7"x7"x89 1/2" (178x178x2274)
ARM REST - W4L13038
1 3/8"x4 5/8"x26" (34x118x660)
D7
(2)
Wood Components (Not to Scale)
Owner's Manual 9205215 - Parts Identification
TABLE TOP - W2A02918
1 5/16"x30 1/8"x30 1/8" (34x765x765)
TT1
(1)
12

Owner's Manual 9205338 - Parts Identification
Hardware Components
BOLT HEX BLK
1/2x9 1/2
(18)
H100756
LAG SCREW HEX BLK
1/2x3
(4)
H100843 LAG SCREW BLK
1/2x2
(18)
H100758
LAG SCREW WH BLK
5/16x3 1/2
(38)
H100482 BOLT WH BLK
5/16x1/2
(18)
H100396
BOLT WH BLK
5/16x1
(4)
H100468
NUT BARREL WH BLK
1/4x5/8
(18)
H100404
LAG SCREW WH BLK
5/16x1 1/2
(26)
H100471
SCREW PFH BLK
8x1 1/2
(17)
H100200
SCREW PFH BLK
8x1 3/4
(26)
H100382
BOLT WH BLK
5/16x1 1/2
(4)
H100407
NUT LOCK BLK
1/2
(18)
H100753
T-NUT BLK
5/16
(4)
H100379
SCREW PWH BLK
8x1
(76)
H100797
WASHER FLAT BLK
1/2
(56)
H100755
WASHER SPLIT
1/2
(17)
H100754
WASHER FLAT BLK
8x19
(13)
H100630
WASHER LOCK EXT BLK
6x15
(17)
H100405
WASHER LOCK EXT BLK
8x15
(17)
H100400
SCREW PWH BLK
8x5/8
(17)
H100202
LAG SCREW WH BLK
5/16x2
(4)
H100458
13

Owner's Manual 9205338 - Parts Identification
Hardware Components
WASHER LOCK EXT BLK
8x19
(44)
H100198
WASHER LOCK EXT BLK
12x19
(22)
H100199
TORX WRENCH T-30
(2)
H100114
TORX BIT
T-30
(2)
H100147
TORX WRENCH T-40
(2)
A100041
TORX BIT
T-40
(2)
A100042
SCREW SETTER
(1)
H100764
SCREW CONCRETE ANCHOR
1/4x2
(13)
H100120 BOLT WH BLK
1/4x1
(18)
H100171
NUT BARREL WH BLK
5/16x7/8
(22)
H100192
14

Owner's Manual 9205017 - Parts Identification
Hardware Components
BOLT WH BLK
1/4x1
(38)
H100171
SCREW PWH BLK
8x5/8
(4)
H100202
NUT LOCK BLK
5/16
(50)
H100479
BOLT CARRIAGE BLK
5/16x1 1/2
(50)
H100712 WASHER FLAT
5/16 BLK
(52)
H100770
SCREW PWH BLK
8x3
(11)
H100824 SCREW PWH BLK
8x3/4
(4)
H100392
LAG SCREW WH BLK
1/4x1
(11)
H100460
LAG SCREW WH BLK
5/16x1 1/2
(11)
H100471
SCREW PFH BLK
8x2
(7)
H100391
H100856
(1)
DRILL BIT
1/4" [6mm]
15

Owner's Manual
Accessory Components (Not to Scale
9205338 - Parts Identification
BRACKET 135° BLK
(2)
A4M01097
L BRACKET
40x40x112 - BLK
(10)
A4M01096
LTP ID TAG
(SMALL)
WITHOUT AGES
(1)
A4M01010
"A" REVISION TAG
(1)
A100314
90° L-BRACKET - BLK
(8)
A4M00555
STEEL POST
ANCHORING
PLATE WITH
FLANGE
(6)
A4M00949 STEEL POST PLATE
(2)
A4M00950
7x7 POST FOOT
(3)
A6P00296
MOUNTING BRACKET
(6)
A6P00364
GROUND STAKE 16 INCH
(6)
A4M00951
16

Owner's Manual
Accessory Components (Not to Scale
9205017 - Parts Identification
FRAME END - LEFT
A4M01060
(1)
POST
(1)
A4M01070
POST
(1)
A4M01069
POST
(1)
A4M01063
ARM POST - RIGHT
(1)
A4M01105
ARM POST - LEFT
(1)
A4M01106
RAIL
(2)
A4M01101 ANGLED RAIL
(4)
A4M01102
SUPPORT
(24)
A4M01064
RAIL
(2)
A4M01065 RAIL
(2)
A4M01095
FRAME END - RIGHT
A4M01066
(1)
SNAP-IN SQUARE PLUG
(5)
A6P00377
90° L-BRACKET - BLK
(2)
A4M00555
17

Owner's Manual
Accessory Components (Not to Scale
9205109 & 9205116 - Parts Identification
SEAT CUSHION
(2)
A6P00392 BACK CUSHION
(4)
A6P00393
DECORATIVE BACK PANEL
(6)
A6P00396
Accessory Components (Not to Scale
Owner's Manual 9205314 & 9205321 - Parts Identification
BACK CUSHION
(4)
A6P00395
SEAT CUSHION
(2)
A6P00394
OR
9205109
CAST SLATE
9205116
SPECTRUM INDIGO
DECORATIVE BACK PANEL
(6)
A6P00411
OR
9205314
BAMBOO PATTERN
9205321
PEBBLE PATTERN
18

CABANA
ASSEMBLY STEP 1
OR
POST - W2A02917
7"x7"x89 1/2" (178x178x2274)
PT3
(1) 7x7 POST FOOT
(1)
A6P00296
STEEL POST
ANCHORING
PLATE WITH
FLANGE
(2)
A4M00949
LAG SCREW BLK
1/2x2
(4)
H100758 SCREW PFH BLK
8x1 1/2
(4)
H100200
WASHER FLAT BLK
1/2
(4)
H100755
200 (x4)
SCREW - 1 1/2"
758 (x4)
LAG SCREW - 1/2x2
755 (x4)
WASHER - 1/2"
949 (x2)
STEEL POST ANCHORING PLATE WITH FLANGE
296 (x1)
7x7 POST FOOT
PT3 (x1)
POST
NOTE HOLES FOR
PROPER ORIENTATION.
19

CABANA
ASSEMBLY STEP 2
LAG SCREW BLK
1/2x2
(8)
H100758 SCREW PFH BLK
8x1 1/2
(6)
H100200
WASHER FLAT BLK
1/2
(8)
H100755
7x7 POST FOOT
(1)
A6P00296
STEEL POST
ANCHORING
PLATE WITH
FLANGE
(2)
A4M00949
PT2 POST - W2A02916
(1) 7"x7"x89 1/2" (178x178x2274)
STEEL POST PLATE
(2)
A4M00950
OR
"A" REVISION TAG
(1)
A100314
23/8in
[60mm]
NOTE HOLES FOR
PROPER ORIENTATION.
PT2 (x1)
POST
200 (x4)
SCREW - 1 1/2"
200 (x2)
SCREW - 1 1/2"
755 (x8)
WASHER - 1/2"
758 (x8)
LAG SCREW - 1/2x2
950 (x2)
STEEL POST PLATE
314 (x1)
"A" REVISION TAG
949 (x2)
STEEL POST ANCHORING PLATE WITH FLANGE
296 (x1)
7x7 POST FOOT
20