Backyard Play Systems ULTRA PLAYSET 4098 User manual

2293-SB
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:
[e-mail]
Our staff is ready to provide assistance.
STOP!
STOP!
- 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.

4HISPAGEINTENTIONALLYLEFTBLANK

12/18/2012
First...
Check with your homeowner’s association before
assembling.
Read instructions thoroughly before you begin. If you
have purchased accessories to accompany this playset,
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
Sockets:
•7/16"
•9/16"
Socket Extension
Ratchet
Hammer
5 lb. Sledge
9/16" Combination
Wrench
#2 Square Drive
Bit (included)
Phillips Bit
Combo Drive Bit
Cordless Drill
w/Charger
Drill Bits:
•1/8"
•1/4"
•7/16"
•7/8"
Tape Measure
Level
C - Clamps
8' Step Ladder
Customer Service
1-866-890-2211
1000 Ternes
Monroe, MI 4816 ULTRA PLAYSET
Model 4098,
6315
Backyard Play Systems
2293-SB
Recommended for Ages 3 to 11
- 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.
- 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.

2
(This page intentionally left blank.)

3
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 bolts 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.

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.
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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 CONTACT THE STORE OR RETURN YOUR 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*


SAFETY WARNINGS
This playset has been designed for use by a maximum of ten occupants at one time having a combined
weight of 1,500 pounds. (This weight does not include occupants on the optional monkey bars, glider, or tire swing).

This playset is recommended for children (3) through (11) years of age.
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Instruct children not to walk close to, in front of, behind, or between moving items.
Instruct children not to twist swing chains or ropes or loop them over the top support bar since this may
reduce the strength of the chain or rope.
Instruct children to avoid swinging empty seats.
Teach children to sit in the center of the swings with their full weight on the seats.
Instruct children not to use the equipment in a manner other than intended.
Instruct children not to get off equipment while it is in motion.
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while using equipment).
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Verify that suspended climbing ropes, chain, or cable are secured at both ends.
Verify that suspended climbing ropes, chain, or cable cannot be looped back on itself.
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use with the equipment, such as, but not limited to, jump ropes, clothesline, pet leashes, cables and
 FKDLQDVWKH\PD\FDXVHDVWUDQJXODWLRQKD]DUG
Instruct children to remove their bike or other sports helmet before playing on the playground equipment.
Instruct children to not walk or run up slides.
Instruct children to not pick up slides or ramps as this may cause damage or breakage.
 3ODFHWKHHTXLSPHQWRQOHYHOJURXQGQRWOHVVWKDQVL[IHHWIURPDQ\REVWUXFWLRQV%HVXUHWRORRN
overhead for any obstructions above the playset.
Do not use the equipment until fully erected per this playset instruction manual, bolts tightened and
the playset is anchored to the ground.
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.

5
MAINTENANCE
Activity on your playset and optional accessories may loosen fasteners. Check all lock nuts, hex and
lag bolts, quick clips, spring clips, 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.
Checking, splitting and surface cracking are characteristics of all wooden playsets. This is caused by varying
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playset with a water repellent.
Tighten all hardware.
Lubricate all metallic moving parts per manufacturer’s instructions.
Check all protective coverings on bolts, pipes, edges, and corners. Replace if they are loose, cracked, or missing.

Check all moving parts including swing seats, ropes, cables, and chains for wear, rust, or other deterioration. Replace as needed.
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Check all wood members for deterioration and splinters. Sand down splinters and replace deteriorating wood members.
Reinstall any plastic parts, such as swing seats or any other items that were removed for the cold season.
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Tighten all hardware.
Check all protective coverings on bolts, pipes, edges, and corners. Replace if they are loose, cracked, or missing.
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Lubricate all metallic moving parts per manufacturer’s instructions.
Check all moving parts including swing seats, ropes, cables, and chains for wear, rust, or other deterioration. Replace as needed.
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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.
Buyer and/or owner should disassemble and dispose of the playground equipment in such a way that no unreasonable hazards will
exist at the time the swing set is discarded. Do not burn your playset's preserved wood.
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 season:


PLAYGROUND SURFACING MATERIALS
SECTION 4 OF THE CONSUMER PRODUCT SAFETY COMMISSION’S OUTDOOR HOME
PLAYGROUND SAFETY HANDBOOK9
Select Protective Surfacing
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and around your play equipment. The protective surfacing should be applied to a depth that is suitable for the equipment height in accordance with
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NOTE: Do not install home playground equipment over concrete, asphalt, or any other hard surface. A fall onto a hard surface can result in
serious injury to the equipment user. Grass and dirt are not considered protective surfacing because wear and environmental factors can reduce
their shock absorbing effectiveness. Carpeting and thin mats are generally not adequate protective surfacing. Ground level equipment – such as
a sandbox, activity wall, playhouse or other equipment that has no elevated play surface – does not need any protective surfacing.
Maximum fall height for this playset is 82”.
Loose-Fill Materials:
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UXEEHUPXOFKIRUHTXLSPHQWXSWRIHHWKLJKDQGLQFKHVRIVDQGRUSHDJUDYHOIRUHTXLSPHQWXSWRIHHWKLJK127($QLQLWLDOÀOOOHYHORI
12 inches will compress to about a 9- inch depth of surfacing over time. The surfacing will also compact, displace, and settle, and should be
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Use containment, such as digging out around the perimeter and/or lining the perimeter with landscape edging. Don’t forget to account for
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play equipment support posts. That way you can easily see when to replenish and/or redistribute the surfacing.
Do notLQVWDOOORRVHÀOOVXUIDFLQJRYHUKDUGVXUIDFHVVXFKDVFRQFUHWHRUDVSKDOW
Poured-In-Place Surfaces or Pre-Manufactured Rubber Tiles:
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Installations of these surfaces generally require a professional and are not “do-it-yourself” projects.
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injury. This height should be equal to or greater than the fall height – vertical distance between a designated play surface (elevated surface for
standing, sitting, or climbing) and the protective surfacing below – of your play equipment.
Check the protective surfacing frequently for wear.
Placement
Proper placement and maintenance of protective surfacing is essential. Be sure to
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the swing is suspended.
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2H 2H
H
L
6 ft.
6 ft.
6 ft. 6 ft.
L+6 ft.
6 ft.
6 ft.
Use Zone for Single-Axis Swings Use Zone for Multi-Axis Swings
Denotes Use Zone with Protective Surfacing
Denotes Use Zone with Protective Surfacing
9This information has been extracted from the CPSC publications “Playground Surfacing—Technical Information Guide” and “Handbook for Public
3OD\JURXQG6DIHW\µ&RSLHVRIWKHVHUHSRUWVFDQEHREWDLQHGE\VHQGLQJDSRVWFDUGWRWKH2IÀFHRI3XEOLF$IIDLUV86&RQVXPHU3URGXFW6DIHW\
Commission, Washington, D.C., 20207 or call the toll-free hotline: [phone]


PLAYSET ORIENTATION
*Hint -
Throughout this manual references
made to the Left Side, the Right Side
and the Front of the playset serve as
a consistent reminder to help with
assembly:
RIGHT SIDE
FRONT SIDE
LEFT SIDE


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.
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 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
DO NOT OVER-TIGHTEN LAG BOLTS

9
BASE PARTS LIST
WOOD PARTS
[
x2x1
x1
[[
1001-ST
1029-ST
1088-ST
2749-W
2506-ST 1020-ST
2312-ST
2548-ST
2546-ST
1026-ST
1015
1025-ST
1009-ST2542-ST 2545-ST
1085-ST
1021-ST
1051-ST1053-ST
x5 [
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
[[
2315-ST x1
[x1
[[ [[
[[ [[
[[[[
[[
[[
[[
[[
[
[[
[[
[
1037-ST
[[
2537-ST [
[[
[
2325-W
[[
x2
2310-W
[
[[
[[
x1
x1 [
x1
x1
[[ [[
x11
[[
x1
[[
[[
[[
[[
[[
x1
2525-W x2
x2
2547-W
[[
x1 x1
2316-ST 2541-ST
[[
x2
2540-ST
[[
x2
1200-ST
[[
[
1198-ST
[[
x2
[
[[
x2
1201-ST 1202-ST
1199-ST
[[
2568-ST
[[
x1
2567-ST
[[
x20
END
VIEW 2569-ST [
[[
END
VIEW

10
BASE ACCESSORIES
x1 x1 x1
x1 x1
90oAngle Bracket Plate
Square-Hole
BASE HARDWARE
Swing Beam Flat Plate
Spring Clip
Swing Hanger
Plaque
[
x1
[
Safety Handle Binoculars
x3
[
[
x2
Rope
Climbing Rocks - Green
Climbing Rocks - Yellow
Slide
Swing Beam Angled Plate Left Swing Beam Angled Plate RightSwing Beam 90oPlate
[
Plastic Hole-Plug
Angled
[
Angle plug
Green Yellow
2036
2004
2551
2450
2411 2448 2447
2485 2449
2433
Sling Swing
x2
2434
Sling Swing
x1
2097
2438 2442
x3 x1
2405 2617
x2
[/DJ%ROW[
)ODW:DVKHU[

11
3"
x6
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 WASHER
TRUSS HEAD SCREW
3/4"
3/8” LAG BOLT WOODSCREWS
3/8" LOCK NUT
4"
3-1/2"
3/8"
2-1/2"
3"
1-1/4"
2-1/2"
PAN HEAD SCREW
2-1/2"
1-5/8" 1-3/4"
x26
2"
x11
x5 x11
x72
x49
x4 x8
x90 x63 x44x240
x5
x6
x94
x12
x8 x5
1/4” ROCK WALL HARDWARE
T - Nut
Lock
Washer
Hex Bolt
2452 (2) BAGS
Flat
Washer
1-1/2"
1/4" SAFETY HANDLE HDW.
Lag
Screw Flat
Washer
1-1/2"
ACTUAL SIZE SHOWN
#2 SQUARE DRIVE BIT
x1

12
ACTUAL SIZE SHOWN
5-1/4"5"
3/8"
4-1/2"
3/8"
4"
3/8"
3/8"
2"
3/8"
1-1/2"
3/8"
1-1/4"
3/8"
2-1/2"
3/8"
3-1/2"
3/8"
3-3/4"
3/8"
5-1/2"
3/8"
6"
3/8"
x4 x2
x2 x16
x1
x4
x1
x14
x2 x1 x1
x2

13
3/8" TORQUE
WASHER
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
3-1/2"
3-3/4" 4-1/2" 7"6-1/2" 9"
x2
x6 x2 x2 x12
x16
x1
ACTUAL SIZE SHOWN


TOWER & BRIDGE PARTS LIST
x2
[
[
WOOD PARTS HDW.
x1
[
[
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
x5
[
[[
[[
x25
[[
[[
[[
x1 x1 x2
[[
[[ [[
[[µ
x1
[
x2
[[
[[
x1
[[
x2
[
[[
[[
x5
Metal Handrail
x1
x1
9" Hand Grip
[[
x1
[[
x1
[[
x2
2327-ST
2328-ST
2329-W
2336-ST
1113-ST
2334-ST
1116-ST
1120-ST
2084
1020-ST
2405 2083
1124-ST
1114-ST
1015
1123-ST
1051-ST
2330-ST
2331-ST
1115-ST
1117-ST
1119-W
1121-ST
2326-ST
2537-ST
[[ [[
[[ [[
[[
[[
[[
x1
1118-ST
[[
2222-ST x1
[[
x1
2313-ST
Round-Hole
90oAngle Bracket
x1
2335-ST

15
1-1/2"
x6
3/8 x 1-1/2"
BUTTON HD SCREW
1"
1/4" x 1" FENDER
WASHER
x3
3/8" T - NUT 3/8" FLAT WASHER
3/8" LOCK WASHER
1/4 " SAFETY HANDLE HDW.
Lag
Screw Flat
Washer
1-1/2 "
3/8" HEX HEAD BOLTS
4"
3/8"
2-1/2"
3/8"
3"
3/8"
5-1/2"
3/8"
x4
x6
1-1/2"
3/8”
x6
x2
3-3/4"
3/8"
x8 x11
#2 SQUARE
DRIVE BIT
x1
2-1/2”
PAN HEAD
SCREW
2-1/2"
x55
x45
x2
x3
x55
3"
x4
3/8” LAG BOLTS
4"
x4
WOODSCREWS
2-1/2"
3"
1-1/4"
x84
x40 x100
TOWER & BRIDGE FASTENERS


29'-5"
17'-5"
6'SAFETY AREA
6'SAFETY AREA
19'-10"
31'-10"
11'-1"
HEIGHT
SET-UP
SWING
ROCK
WALL
TOWER
LEFT SIDE RIGHT SIDE
FRONT SIDE
BACK SIDE
SLIDES
ORIENTATION
This space intentionally left blank.


FORT PARTS LAYOUT
RIGHT
FRONT
*IMPORTANT!
Lay Out Corner Posts
as shown.
IMPORTANT!
Install 1001-ST with
counterbores oriented
as shown.
FORT CORNER POSTS / FLOOR SUPPORTS
3/8
”
x5
-
1/4
”
Hex Bolts
T-Nut
Flat Washer
Lock Washer
LEFT SIDE
RIGHT SIDE
LEFT
[
[[
1029-ST
[
[[
2312-ST
x1
[[
2545-ST
x2
[[
2310-W
x2
[[
2547-W
[
[[
1001-ST
x2
[[
1001-ST
x2
[[
1001-ST
x2
[[
2310-W
x2
[[
2547-W
Note 2547-W
hole location.


FORT CORNER POSTS / FLOOR
2-1/2" Wood Screws x52
Board will
ovehang.
Flush
48"
Outside of Posts
Outside of Posts
48"
56-1/2" 56-1/2"
[
[[
1029-ST
[
[[
2312-ST
x1
[[
2545-ST
FORT CORNER POSTS / FLOOR
T-Nut x14
3UHÀWGHFNERDUGVVR
they are evenly spaced
before installing screws.
Center boards between
48" and corner posts.
Make sure corner
posts are squared to
measurements shown.
NOTE:
HOLE LOCATIONS
OF 2547-W.