Backyard Play Systems 4105 User manual

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 7:00 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:
[e-mail]
Our staff is ready to provide assistance.
STOP!
STOP!
2054
- NOTICE -
This playset product is not intended for public use. It is intended for
residential application and is not warranted for public or commercial use.

(This page intentionally left blank.)

04/09/2009
- 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 minor cracks/splits. All individual parts have been cut to provide a smooth and safe surface. All parts have been inspected to
assure we pack only the safest, most durable wood product. Any minor blemishes in your playset will not affect the strength, durability, or structural integrity
of the finished product. Our limited warranty does not cover the imperfections not resulting in structural failure.
2054
Playset Model 4105
First...
Check with your homeowner’s association before
assembling.
Read instructions thoroughly before you begin. If you
have purchased accessories to accompany this play
set, please read all installation instructions before
beginning assembly of this structure.
Check All Parts
If a part is missing, circle the part in question and call.
Important
In a drawing, a dotted line represents a part hidden
from view (like a part under a panel).
Adult Assistance required
Assistance is necessary to handle, fit, and
secure some components.
Squareness is very Important!
Start with a level surface and keep 90° corners and 90°
perpendiculars throughout the assembly to ensure all
components fit together.
Safety!
Check for protruding screws and bolts, verify all screw
and bolt lengths during assembly.
Always wear OSHA-APPROVED safety
glasses throughout assembly process.
Tools Required
SocketSet
Hammer
5lb. Sledge
9/16”Combination
Wrench
#2SquareDrive
Bit (included)
PhillipsBit
CordlessDrill
w/Charger
1/8”DrillBit
1/4”DrillBit
1/2”DrillBit
TapeMeasure
Level
C - Clamps
8'Step Ladder
Framing/Speed
Square
- BEFORE YOU BEGIN -
Recommended for Ages 3 to 11
Backyard Play Systems
Customer Service
1-866-890-2211
1000 Ternes Drive
Monroe, MI 48162
- NOTICE -
This playset product is not intended for public use. It is intended for
residential application and is not warranted for public or commercial use.

2
ASSEMBLY SAFETY and HELPFUL HINTS
Wear safety glasses during drilling, assembly of your playset.
Children should not be allowed in the playset assembly and build area.
Note the hole orientation on parts to avoid having to take parts
apart later.
Some steps require the assistance of two people to ensure proper
assembly, safety during assembly, as well as preventing any damage
to the playset.
All hex bolts and lag screws require a lock washer or lock nut.
To properly install lock nuts, two to three threads must protrude past the
lock nut and be exposed once tightened.
Acorn nuts provide protection in case screw threads protrude past a
surface. Extra acorn nuts are provided for this reason. Please be certain
to use these acorn nuts in the event this condition arises.
If a bolt does not engage in a T-Nut, it may be necessary to first install
without the washers and “grab” the T-Nut. Then back-out the bolt
and install with specified washers.
Due to wood characteristics and the manufacturing process hex bolts
may protrude past a surface. If this condition occurs add additional
supplied washers to eliminate bolt protrusion.
To aid in proper assembly pound T-nuts into their respective hole
prior to assembly
Pound in T-nuts while the part is on the ground to ensure proper seating.
Use a soft material under parts when pounding in T-nuts to ensure
no scratching or de-facing of parts.
Make sure all fasteners used are as specified. Using a fastener not
specified in a particular application may result in too much thread
exposure or not enough thread engagement.
ASSEMBLY SAFETY and HELPFUL HINTS
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 CONTACTTHE STORE OR RETURNYOUR PLAYSET !
KEEP THIS INSTALLATION MANUAL FOR FUTURE CARE
AND MAINTENANCE REFERENCE.
To aid in making your playset assembly easier,
here is a listing of some helpful hints.
*IMPORTANT HARDWARE INFORMATION*

3
SAFETYWARNINGS
Thisplaysetisrecommendedforchildren(3) through (11) yearsofage.
Adultsupervisionisrequiredforchildrenofallages.
Dresschildrenappropriately.Avoidloosefitting clothes, coats, scarves,drawstringsandother
articlesof clothing thatmay get caughtin the swingset.
Instructchildrentouseequipmentsensibly.
Childrenshouldnottwist rope or chains.
Childrenshould avoid swingingempty seats.
Childrenshouldsit in the centerofthe seat, withtheirfull weight ontheseat.
Neverallow children tostand orkneel on aswing.
Onlyone child per swing at a time.
Childrenshouldnotgetoffmovingequipment.
Childrenshouldnotwalk close to, infrontof,behind, or between movingitems.
Childrenshouldnot walk orrunup slide.
Childrenshould notpick up ramps or slides as this may causebreakage.
Ourequipment should notbe installed orerected on anyhard surface suchas asphalt, concrete
orpackedearth. A fall ontoa hard surfacecanresult in seriousinjury to theequipmentuser.
Placetheequipment on levelgroundnot less thansix(6) feet fromanyobstructions.
Donotusetheequipmentuntilfullyerected,boltstightened,andstructureis anchored to the ground.
Children should not play on the playset when it is wet. Slippery surfaces may cause a hazard.
Verifythat suspended climbing ropes, chains,or cablesare secured at both endsand cannot
belooped backon itself.
Donot loop chains or ropes over theirtop supportsso asnot to reduce the strength
ofthese ropesand chains.
Instructchildrennottoattach items to theplaygroundequipmentsuchas, but not limitedto,jumpropes,
clothesline,pet leashes,cables and chain as they may cause a strangulationhazard.
Instructchildren to notuse this playset or anypart of itfor anyother purpose thanits intendeduse.
Forsafety do not cut endsof ropesas thismay cause an unraveling condition.Instead, tieknots
inendof remaining ropekeepingends intact andsealed.
Please read carefully. Observing the following statements and warnings
reduces the likelihood of serious or fatal injury.
NOTICE:
This playset product is not intended for public use. It is intended for residential application
and is not warranted for public or commercial use.
These statements are in accordance with the Consumer Safety Standards Guide.

4
MAINTENANCE
Activity on your playset and optional accessories may loosen fasteners. Check all
lock nuts, hex and lag bolts, quick clips, retainer rings, acorn nuts, wood screws
and swing hangers for tightness and tighten as required.T-nuts should be
inspected for full and proper seating into the wood. Check and tighten all fasteners
twice monthly during the usage season. It is particularly important that this
procedure be followed at the beginning and end of each season.
Checking and surface cracking are characteristics of all wooden playsets. This is
caused by seasonal varying temperatures and moisture conditions. To minimize this
checking and/or cracking you may coat your playset with a sealant or preservative.
The color of your playset is from a process called MicroShade ™ and involves adding
colorant into the wood as it is pressure treated. It means colorant is throughout the
wood which helps minimize any surface marking being visible. The appearance of your
playset with MicroShade will last about two years with no stain or water sealant
application. You may wish to apply a water sealant which will benefit the wood and help
minimize splitting and checking.
If the stakes that anchor the set down become loose, detach them, drive them into the
ground in a different area and screw them to the set again.
All hardware is plated to prevent premature rusting. Although they are plated, some
may eventually experience surface rust. This will not affect their strength.
Oil all metallic moving parts monthly during the usage period. To eliminate squeaks,
spray with WD-40 or other household lubricant.
Check swing seats, ropes, cables, and chains monthly during usage season for
evidence of deterioration.
Check rope on all accessories for extensive wear.
To help prevent pre-mature deterioration of rope and accessories,
detach and store during the off season.
Instruct your children not to twist ropes or chains, since this may reduce
the strength of the rope or chain.
Tents, Sandbox Cover, Trapeze, Tire, Swings and Slides should be removed
and stored indoors once temperature turns 10°F. or lower. Extended exposure to
these temperatures can shorten the life of your swing sets components.
When you are ready to dispose of your playset, make sure that all
metal, plastic and wood components are disposed of in accordance
with local waste ordinances.
Periodic maintenance is required to ensure safe enjoyment
of your playset and accessories.

5
PLAYGROUND SURFACING MATERIALS
X3.CONSUMERINFORMATION SHEET FOR PLAYGROUND SURFACING MATERIALS 9.
X3.1TheU.S.Consumer Product SafetyCommission(CPSC) estimates that about100,000playground equipment
relatedinjuriesresultingfromfallstothegroundsurfacearetreatedannuallyinU.S.hospitalemergencyrooms. Injuries
involvingthis hazard patterntend tobe among themost seriousof all playgroundinjuries, andhave the potentialto be
fatal,particularly when theinjury is tothe head. Thesurface under andaround playground equipment can bea major
factorindetermining the injury-causingpotential of afall.It is selfevident that afallonto a shockabsorbing surface isless
likelyto cause a serious injurythan a fall onto ahard surface.Playground equipment should never beplaced on hard
surfacessuch as concrete or asphalt and while grass may appear to be acceptable it may quickly turnto hard packed
earthinareas of hightraffic.Shredded bark mulch,woodchips, fine sand orfine gravel areconsideredto be acceptable
shockabsorbingsurfaces when installedand maintained atasufficient depth underand around playgroundequipment.
X3.2TableX3.1 lists themaximumheight from whicha child would notbe expected tosustaina life-threatening head
injuryinafallontofour different loose-fill surfacingmaterialsiftheyare installed and maintained atdepthsof6,9,
and12 in.
However,itshould be recognizedthatall injuries duetofalls cannot bepreventedno matter whatsurfacingmaterial
isused.
X3.3 Itisrecommendedthata shock absorbing materialshouldextenda minimum of 6ftinall directions from the
perimeterofstationaryequipment such as climbersandslides.However, because childrenmaydeliberatelyjump from a
movingswing, the shockabsorbing material shouldextend in the front andrear of aswing a minimumdistance of2
timestheheightofthe pivot pointmeasuredfromapoint directly beneath thepivotonthe supporting structure.
X3.4Thisinformationisintendedto assist in comparing therelativeshock-absorbingpropertiesofvarious materials. No
particularmaterialisrecommendedoveranother.However,eachmaterialisonlyeffectivewhenproperlymaintained.
Materialsshouldbecheckedperiodicallyandreplenishedtomaintaincorrectdepth as determined necessary for your
equipment.Thechoice of amaterial depends onthe type andheight of theplayground equipment theavailability of the
materialinyour area, and itscost.
9ThisinformationhasbeenextractedfromtheCPSCpublicationsPlaygroundSurfacing—TechnicalInformationGuide”
and“Handbook forPublic PlaygroundSafety.” Copies of these reports can be obtained by sending a postcard to the:
OfficeofPublicAffairs,U.SConsumerProductSafetyCommission,Washington,D.C.,20207orcallthe toll-free hotline
:1-800-638-2772
TABLE X3.1 Fall Height in Feet From Which a Life Threatening
Head Injury Would Not Be Expected
6 in. depth 9 in. depth 12 in. depthType of Material
61011Double Shredded Bark Mulch
6712Wood Chips
559Fine Sand
6710Fine Gravel

6
ORIENTATION
*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
PLAYSET
RIGHT SIDE

7
IMPORTANT!
AA
B
B
Use these Assembly Procedure Hintsthroughout the installation process.
1. All Lag Bolts must have pre-drilled holes. Use a 1/4” drill bit for all 3/8” Lag Bolts.
Pre-drilling pilot holes will help prevent Screws and Lag Bolts from breaking and
wood from splitting during assembly.
2. In areas where drilling a larger 1/2” hole is neccessary, such as when installing T-Nuts,
(Fig. 1) the recommended procedure is to first drill-through a 1/4” pilot hole from the
Hex Bolt side and then drill the larger 1/2” hole from the opposite T-Nut side. This will
help avoid splintering the wood. The “Drill Both SidesICON” (Fig. 1) will remind you to
drill according to this procedure. Be sure to clean through-holes of debris before
inserting Hex Bolts.
3. When assembling parts that are difficult to hold in position while pre-drilling pilot holes
or assembling, use a clamp to keep parts aligned or in position. The “Clamp ICON”
(Fig. 2) will advise you to use this procedure.
Fig. 1 (example)
Fig. 2
Drill Both Sides
ICON
Clamp ICON
1/4”pilot hole
1/2”drill through

8
WOOD PARTS LIST
x1
x1
x4
WOOD PARTS
x22 x4
5/4 x 4 x 47-7/8”
x2
x1
2 x 4 x 38-1/2”
x1
x2
5/4 x 6 x 43-3/8”
2-3/4 x 3-3/8 x 83-7/8”
x2
x9
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”..........................................1”x 3-1/2”
5/4“ x 6”..........................................1”x 5-1/2”
2“ x 4”.......................................1-3/8” x 3-3/8”
2“ x 6”.......................................1-3/8” x 5-3/8”
4“ x 4”.......................................3-1/4” x 3-1/4”
..........................................
x1
x2
5/8 x 3-1/4 x 34-1/8”
x6
x1
x5
5/4 x 4 x 47-7/8”
2 x 4 x 15-3/8”
2 x 4 x 52-1/2”
5/4 x 6 x 68-1/4”
2 x 4 x 52-1/2”
x4
5/4 x 6 x 45-3/8”
x4
2 x 4 x 18”
5/4 x 6 x 71-3/4”
x8
x5
2 x 4 x 45-3/8”
x1
5/4 x 3 x 71-3/4”
2 x 4 x 71-3/4”
2-3/4 x 5-3/8 x 95”
x2
2 x 4 x 66-1/8”
2 x 4 x 52-1/2”
1 x 1-3/8 x 17”
2-3/4 x 3-3/8 x 92”
5/4 x 6 x 35-3/4”
x1
2 x 4 x 95”
1167-MS 1168-MS
1166-MS 1165-MS
1164-MS 1178-MS 1179-MS
1169-MS 1015 1051-MS
1163-MS 1162-MS
1038-MS 1183-MS
1172-MS 1173-MS
1161-MS 1017-MS 1182-MS
1180-MS 1171-MS
1174-MS 1170-MS

9
ACCESSORIES
x1
HARDWARE
x6
x1
Safety Handle
x2
x4
x1
x8
x1
Tent Tarp Plaque
x1x2
x16
x6
Trapeze
Swing Climbing Rocks
Swing Beam Flat Plate Swing Beam Bent Plate Swing Beam Top Bracket
Swing Hanger Spring Clip L - Bracket
x4
x1
Metal Handrail
x4
x1
Telescope Steering Wheel
x1
Slide
x1
2098-B 2106-B 2108-B
2003 2004 2084-B
2097-BY 2096-Y 2095-BY
2012-BY 2035 2007-Y
2099-Y 2073-BY 2008-B2083-B

10
PLAYSET FASTENERS
1” 1”
3/8”T - NUT
3/8” FLAT WASHER
1/4”x 1” FENDER WASHER 3/16” x 1”FENDER WASHER
3/8”LOCK WASHERTRUSS HEAD SCREW
3/4”
3/8”LOCK NUT
2-1/2”
PAN HEAD SCREW
2-1/2”
3/8”ACORN NUT
3/8”3/8”
3/8”3/8”
1/4”ROCK WALL HARDWARE
T - Nut
Lock
Washer
Hex Bolt
Flat
Washer
1-1/2”
1/4”SAFETY HANDLE HDW.
Lag
Screw
Flat
Washer
1-1/2”
x12 x6 x45
x124
x94
x2
x8
x8
x2
x8
x16
94

11
PLAYSET FASTENERS
3/8”LAG BOLT WOODSCREWS
3-1/2”
2-1/2”
3”
1-1/4” 1-5/8”
3”
3/8”
3/8”HEX HEAD BOLTS
3-1/2”
2-1/2”
3/8”
1-1/2”
3/8”
3”
3/8”
x4
x8
#2 SQUARE DRIVE BIT
x1
1-1/2”
3/8”
BUTTON HD.
SCREW
x13
x38
x10
x100 x2 x150 x85
x14
x100
2-1/2”
3/8”
BUTTON HD.
SCREW
x1
x1

12
FORT
SET-UP
SANDBOX
SAFETY AREA
FRONT SIDE
BACK SIDE
LEFT SIDE RIGHT SIDE
6’
6’
6’
26’ 4”
6’
SWING
ROCK WALL
SLIDE
25’ 10”
LADDER
Flush
Flush
x2
x21174-MS
1170-MS
5/4 x 6 x 45-3/8”
5/4 x 6 x 43-3/8”
3”Screws x12

13
FORT CORNER POSTS
FORT CORNER POSTS
Flush
Mark and Pre-Drill 1/4”hole one
inch (1”) below upper screw.
Do not drill through corner post.
x4
1183-MS
2-3/4 x 3-3/8 x 83-7/8”
FlatWasher
LockWasher
3-1/2”Lag Bolt
x4
3”Screws x8
1174-MS
5/4 x 6 x 43-3/8”
1”

14
FORT FLOOR FRAME
Flush
T-Nut x4
3”Screws x12
35-7/8”
35-7/8”
Center
FORT FLOOR FRAME
FlatWasher
Lock Washer
2-1/2”Hex Bolt
x2
x3
1163-MS
1162-MS
2 x 4 x 45-3/8”
2 x 4 x 71-3/4”
x4
FlatWasher
Lock Washer
2-1/2”Hex Boltx4

15
FORT FLOOR FRAME
FORT FLOOR FRAME
1/4”
!IMPORTANT!
Mark L-BRACKET locations at
each corner. Ensure 1/4”distance
between L-BRACKET and lower
edge of frame as shown.
Drill-Through 1/4”marked L-BRACKET locations at
each corner.
Re-Drill through using 1/2”bit from outside of frame at each
L-BRACKET hole location.
x4
2084-B
SEE PAGE 8

16
FORT FLOOR FRAME
T-Nut x8
FlatWasher
LockWasher
1-1/2”Hex Bolt x8
FORT DECK PLANKS
Flush
Pre-assemble all deck planks
as shown.
Align all deck planks
flush at ends.
Ensure all deck planks are
evenly spaced.
evenly spaced
Pound in T-Nut at each of eight
L-BRACKET location holes on
outer face of boards as shown.
Flush
x8
x1
1172-MS
1173-MS
5/4 x 6 x 71-3/4”
5/4 x 3 x 71-3/4”

17
FORT FLOOR FRAME
FORT DECK PLANKS
Flush
2-1/2”Screws
x54
Pre-Drill 1/4”hole.
Do not drill through.
Flush
Flush
x2
2 x 4 x 18”
1169-MS

18
FORT FLOOR FRAME
FlatWasher
Lock Washer
3-1/2”Lag Bolt
x4
FORT FLOOR FRAME
CENTER
x2
2 x 4 x 18”
1169-MS