Backyard Products 4030 User manual

STOP!
STOP!
2321
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
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:
[email protected]
[email protected]
Our staff is ready to provide assistance.
- 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.

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03/3/2011
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
7/16” Socket
Ratchet
Socket
Extension
Hammer
5 lb. Sledge
9/16” Combination
Wrench
#2 Square Drive
Bit (included)
Phillips Bit
Combo Drive Bit
Cordless Drill
w/Charger
1/8” Drill Bit
1/4” Drill Bit
Tape Measure
Level
C - Clamps
8’ Step Ladder
Customer Service
1-866-890-2211
1000 Ternes
Monroe, MI 4816 Playset
Model:
4030, 4101,
4090, 4095
Backyard Play Systems
2321
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
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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 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 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*

4
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.
On-site adult supervision for children of all ages is recommended.
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.
Parents should dress children appropriately (examples would include the use of well-fitting shoes and
the avoidance of ponchos, scarves, and other loose-fitting clothing that is potentially hazardous
while using equipment).
Instruct children not to climb when the equipment is wet. Slippery surfaces may cause a hazard.
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.
Instruct children not to attach items to the playground equipment that are not specifically designed for
use with the equipment, such as, but not limited to, jump ropes, clothesline, pet leashes, cables and
chain as they may cause a strangulation hazard.
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.
Place the equipment on level ground not less than six (6) feet from any obstructions. Be sure to look
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
seasonal temperatures and moisture conditions. To minimize this checking and/or cracking you may coat your
playset with a water repellent.
 The color of your playset is from a process called MicroShade ™ and involves adding pigment into the wood
as it is pressure treated. This process results in colorant throughout the wood which helps minimize surface
markings being visible. The appearance of your playset with MicroShade will last about two years with no
stain application. You may wish to apply a water repellent which will benefit the wood and help minimize
splitting, checking and surface cracking
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.
Check metal parts for rust. If found, sand and repaint using a nonleaded-based paint meeting the requirements of 16 CFR 1303.
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.
Rake and check depth of loose fill protective surfacing materials to prevent compaction and to maintain appropriate depth. Replace as necessary.
Tighten all hardware.
Check all protective coverings on bolts, pipes, edges, and corners. Replace if they are loose, cracked, or missing.
Rake and check depth of loose fill protective surfacing materials to prevent compaction and to maintain appropriate depth. Replace as necessary.
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.
At the end of each play season or when the temperature drops below 10°F remove plastic swing seats, tents, sandbox cover, tire swing,
slide and other items as specified by the manufacturer and take indoors or do not use.
Rake and check depth of loose fill protective surfacing materials to prevent compaction and to maintain appropriate depth.Replace as necessary.
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:

6
PLAYGROUND SURFACING MATERIALS
SECTION 4 OF THE CONSUMER PRODUCT SAFETY COMMISSION’S OUTDOOR HOME
PLAYGROUND SAFETY HANDBOOK9
Select Protective Surfacing
One of the most important things you can do to reduce the likelihood of serious head injuries is to install shock-absorbing protective surfacing under
and around your play equipment. The protective surfacing should be applied to a depth that is suitable for the equipment height in accordance with
ASTM Specification F 1292. There are different types of surfacing to choose from; whichever product you select, follow these guidelines:
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:
Maintain a minimum depth of 9 inches of loose- fill materials such as wood mulch/chips, engineered wood fiber (EWF), or shredded/recycled
rubber mulch for equipment up to 8 feet high; and 9 inches of sand or pea gravel for equipment up to 5 feet high. NOTE: An initial fill level of
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
periodically refilled to maintain at least a 9- inch depth.
Use a minimum of 6 inches of protective surfacing for play equipment less than 4 feet in height. If maintained properly, this should be
adequate. (At depths less than 6 inches, the protective material is too easily displaced or compacted.)
Use containment, such as digging out around the perimeter and/or lining the perimeter with landscape edging. Don’t forget to account for
water drainage. U.S Consumer Product Safety Commission, Washington, D.C., 20207 or call the toll-free hotline :[phone]
Check and maintain the depth of the loose-fill surfacing material. To maintain the right amount of loose-fill materials, mark the correct level on
play equipment support posts. That way you can easily see when to replenish and/or redistribute the surfacing.
Do not install loose fill surfacing over hard surfaces such as concrete or asphalt.
Poured-In-Place Surfaces or Pre-Manufactured Rubber Tiles:
You may be interested in using surfacing other than loose-fill materials – like rubber tiles or poured-in-place surfaces.
Installations of these surfaces generally require a professional and are not “do-it-yourself” projects.
Review surface specifications before purchasing this type of surfacing. Ask the installer/manufacturer for a report showing that the product
has been tested to the following safety standard: ASTM F 1292 Standard Specification for Impact Attenuation of Surfacing Materials within the
Use Zone of Playground Equipment. This report should show the specific height for which the surface is intended to protect against serious head
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
Extend surfacing at least 6 feet from the equipment in all directions.
For to-fro swings, extend protective surfacing in front of and behind the swing to a distance equal to twice the height of the top bar from which
the swing is suspended.
For tire swings, extend surfacing in a circle whose radius is equal to the height of the suspending chain or rope, plus 6 feet in all directions.
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
Playground Safety.” Copies of these reports can be obtained by sending a postcard to the: Office of Public Affairs, U.S. Consumer Product Safety
Commission, Washington, D.C., 20207 or call the toll-free hotline: [phone]

7
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

8
IMPORTANT!
AA
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.
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 Sides ICON” (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

9
BASE PARTS LIST
x1
x4
x4
WOOD PARTS
x4
x2
x1
x2
3 x 3 x 77"
5/4 x 6 x 67-1/2"
x4
1037-MS1038-MS
2325-MS
1001-MS
1029-MS
1088-MS
2314-MS
1017-MS 1020-MS
2312-MS
1026-MS
1210-MS
1015-MS
1025-MS
1009-MS 1033-MS
2311-MS
2310-MS
1085-MS
1024-MS
1023-MS
1022-MS
1021-MS
2316-MS 1051-MS
2315-MS
1053-MS
x5 x6
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”
..........................................
x2x1
2 x 6 x 75-1/2"
x1 x6
x1
1 x 4 x 56-1/2"
2 x 4 x 59-1/8"
2 x 4 x 15"
2 x 4 x 15-3/8"
2 x 4 x 51"
3 x 3 x 92-1/2"
5/4 x 6 x 68-1/4"
x4
2 x 4 x 19"
2 x 4 x 18"
x16
3 x 3 x 44-1/8"
x8
5/4 x 6 x 47-3/4"
5/8 x 3-1/4 x 34-1/2"
x2
x1 x4
5/4 x 4-1/4 x 47-3/4" 5/4 x 6 x 41-1/2"
x2 x11
2 x 4 x 43-1/2" 5/4 x 6 x 47-3/4"
x1
1-x 1-3/8 x 17"
2-3/4 x 5-3/8 x 94-1/2"
2 x 4 x 65-1/8"
2 x 6 x 84"
2 x 4 x 69-1/2"2 x 4 x 51"
x2
2 x 4 x 47-7/8"
x1
x2
2 x 4 x 96"

10
BASE ACCESSORIES
x2
Swing Beam Flat Plate
BASE HARDWARE
Swing Beam Flat Plate
Spring Clip
Swing Hanger
Plaque
x6
x1
x6
Sling SwingTrapeze Bar
Safety Handle
x2Green
x3x3
x1
x1
x13
x1
Rope Tent Tarp
Climbing Rocks
Slide
x1
Swing Beam Angled Plate
x4
Plastic Hole-Plug
Angled
x1
x4 x26
2098-H
Angle plug
2167
2106-H
2004
2014
2023
2003
2000
2017-B
2074
2082 2015 2007

11
3”
x24
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”
x11
3/8” ACORN NUT
3/8” x3
x8
x3 x8
x87
x42
x4 x16
x72 x45 x42x149
x3
x6
x107
x26
1/4” ROCK WALL HARDWARE
T - Nut
Lock
Washer
Hex Bolt
Flat
Washer
1-1/2”
x22
1-3/4”
No. 8
1/4” SAFETY HANDLE HDW.
Lag
Screw Flat
Washer
1-1/2”
ACTUAL SIZE SHOWN
#2 SQUARE DRIVE BIT
x1

12
5-16 ”
LAG BOLT
3”
x8
5/16” FLAT WASHER
5/16” LOCK WASHER
5/16”
5/16”
x4
x8
3/8”
5-1/4”
3-1/2”
4”
3/8”
3-3/4”
3/8”
3/8”
2-1/2”
3/8”
3”
3/8”
5-1/2”
3/8”
3/8”
10”
x4
x1
x19
x4
x2
x16
x2
x2
ACTUAL SIZE SHOWN

13
16’-3”
6’SAFETY AREA
6’SAFETY AREA
15’-1”
11’-1”
HEIGHT
16'-3"
6'SAFETY AREA
6'SAFETY AREA
20'-1"
11'-1"
HEIGHT
SET-UP
SET-UP
ORIENTATION
ORIENTATION
LEFT SIDE
LEFT SIDE
RIGHT SIDE
RIGHT SIDE
FRONT SIDE
FRONT SIDE
SWING
SWING
ROCK
WALL
ROCK
WALL
MONKEY
BARS
SLIDE
SLIDE
BACK SIDE
BACK SIDE
BASE PLAYSET
WITH
MONKEY BARS

14
FORT PARTS LAYOUT
RIGHT
FRONT
*IMPORTANT!
Lay Out Corner Posts
as shown.
IMPORTANT!
Install 1001-MS with
counterbores oriented
as shown.
Orient the 2-holes of 1033-MS
UP if you have the
Tire Swing Option.
Orient the 2-holes of 1033-MS
DOWN if you don’t
have the Tire Swing Option.
FORT CORNER POSTS / FLOOR SUPPORTS
3/8” x 5-1/4” Hex Bolts
T- N u t
Flat Washer
Lock Washer
LEFT SIDE
RIGHT SIDE
LEFT
x8
5/4 x 6 x 47-3/4"
1029-MS
x4
5/4 x 6 x 41-1/2"
2312-MS
x1
5/4 x 4-1/4 x 47-3/4"
1033-MS
x1
5/4 x 4-1/4 x 47-3/4"
1033-MS
x4
3 x 3 x 44-1/8"
2310-MS
x4
2 x 6 x 75-1/2"
1001-MS
x2
2 x 6 x 75-1/2"
1001-MS
x2
2 x 6 x 75-1/2"
1001-MS
x2
3 x 3 x 44-1/8"
2310-MS
x2
3 x 3 x 44-1/8"
2310-MS

15
FORT CORNER POSTS / FLOOR
Wood Screws x52
Board will
ovehang.
Flush
48"
Outside of Posts
Outside of Posts
48"
56-1/2" 56-1/2"
x8
5/4 x 6 x 47-3/4"
1029-MS
x4
1 x 6 x 41-1/2"
2312-MS
x1
5/4 x 4-1/4 x 47-3/4"
1033-MS
FORT CORNER POSTS / FLOOR
T-Nut x12
Pre-fit deck boards so
they are evenly spaced
before installing screws.
Center boards between
48" and corner posts.
Make sure corner
posts are squared to
measurements shown.

16
FORT SIDE WALLS
LEFT SIDE
RIGHT SIDE
Flush
at ends.
Sets on
1001-MS
3" Wood Screws
x 16
Keep 56-1/2" measurement
when installing 1037-MS.
x2
1 x 4 x 56-1/2"
1037 -MS
x2
1 x 4 x 56-1/2"
1037 -MS
35-1/4"
35-1/4"
35-1/4"
35-1/4"
56-1/2"
4” Hex Bolt
Lock
Washer Flat
Washer
4” Hex Bolt
Lock
Washer
Flat
Washer
FORT TENT SIDE RAILS
LEFT SIDE
RIGHT SIDE
x2
2 x 4 x 96"
1023-MS
Install bolts firmly, but do not fully tighten.
Re-adjustment will be neccessary.

17
4” Hex Bolt
Lock Washer
3-1/2” Lag Bolt
3-1/2” Lag Bolt
Flat Washer
4” Hex Bolt
Lock Washer
Flat Washer
Lock Washer
Flat Washer
48"
56-1/2"
56-1/2"
48"
FORT TENT END RAILS
RIGHT SIDE
LEFT SIDE
3" Wood
Screws
(x8)
x2
2 x 4 x 51"
1022-MS
FORT
RIGHT SIDE
UPPER ARMS
LEFT SIDE
x1
2 x 4 x 51"
1009-MS
x1
2 x 6 x 84"
1088-MS
Install bolts firmly, but do not fully tighten.
Re-adjustment will be neccessary.
Check and keep all measurements
while tightening all bolts securely.

18
Temporarily secure two Right Side Legs (2325-MS)
with 5-1/4” Hex Bolts;
Tap Bolts down lightly until Bolts bottom out.
Do not install T-Nuts at this time.
Lock Washer
Flat Washer
Plastic
Angled Plug
5-1/2” Hex Bolt
Tighten Securely
FORT INSTALL LEGS
FORT INSTALL LEGS
RIGHT SIDE
LEFT SIDE
LEFT SIDE
RIGHT SIDE
5-1/4” Hex Bolt with
Lock washer and
Flat Washer
T- N u t
5-1/2” Hex Bolt
T-Nut
5-1/4” Hex Bolt
5-1/2”
Hex Bolt
Flat
Washer Lock
Washer
Plastic
Angled Plug
Plastic
Angled Plug
Plastic
Angled Plug
* Note -
For Safety two people are required
to carefully roll fort over.
x2
3 x 3 x 77"
2325-MS
x2
3 x 3 x 77"
2325-MS