Forpark Australia Fitness Track User manual

INSTALLATION MANUAL
FITNESS TRACK
WWW.FORPARKAUST.COM.AU

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FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL FITNESS TRACK
20 September 2016
CONTENTS
Fitness Track ...........................................................................................................................................................3
Prepare the site.........................................................................................................................................................3
Equipment required for installation ..............................................................................................................................3
Securing the site while work is in progress ...................................................................................................................3
Preparation for installation..........................................................................................................................................4
Concrete Footings......................................................................................................................................................4
Fasteners .................................................................................................................................................................4
Flanges & Rails..........................................................................................................................................................5
FT01a –Chin Up Bar ‘A’ .............................................................................................................................................6
FT01b –Chin Up Bar ‘B’ .............................................................................................................................................6
FT02 –Log Wall ........................................................................................................................................................7
FT03 & FT36 –Rope Swing / Rope Climber ...................................................................................................................8
FT04 –Leap Frog ......................................................................................................................................................9
FT05 –Monkey Bars ................................................................................................................................................10
FT06 –Obstacle Frame ............................................................................................................................................11
FT07 –Sit Up Board.................................................................................................................................................11
FT08 –Chain Net & Frame........................................................................................................................................12
FT09 –Parallel Bars.................................................................................................................................................13
FT10 –Hurdles........................................................................................................................................................14
FT11a –Balance Walkers ‘A’ .....................................................................................................................................14
FT11b –Balance Walkers ‘B’ .....................................................................................................................................15
FT12 –Swinging Balance Beam.................................................................................................................................15
FT13 –Step Up .......................................................................................................................................................16
FT14 –Roman Triangles...........................................................................................................................................16
FT15 –Fireman’s Pole..............................................................................................................................................17
FT16 –Roll Over Bar................................................................................................................................................17
FT17 –Achilles Stretch.............................................................................................................................................18
FT18 –Push Up Bars................................................................................................................................................18
FT19 –Vault Bar .....................................................................................................................................................19
FT20 –Leg Lift Bar ..................................................................................................................................................19
FT23 –Burmese Bridge ............................................................................................................................................20
FT24 –Challenge Rail ..............................................................................................................................................21
FT25 –Arched Roman Triangles ................................................................................................................................21
FT26 –Hang ‘n’ Glide...............................................................................................................................................22
FT28 –Vertical Rung Climber....................................................................................................................................23
FT29 –Tread Mill.....................................................................................................................................................24
FT30 –Combat & Rung Climber ................................................................................................................................25
FT31 –Commando Climber.......................................................................................................................................26
FT32 –Pommel Walker ............................................................................................................................................27
FT33 –Rock Wall & Pole...........................................................................................................................................28
FT34 –Arched Monkey Bar .......................................................................................................................................29
FT35 –Roman Monkey Bar .......................................................................................................................................29
FT39 –Double Sided Rock Wall .................................................................................................................................30
FT40 –Aerobic Stepper ............................................................................................................................................30
FT42 –Stretch Station .............................................................................................................................................31
FT43 –FT Sign........................................................................................................................................................31
FT44 –Steppers......................................................................................................................................................32
FT50 –Parallel Bars (Heavy)......................................................................................................................................32
FT51 –Dip Bars ......................................................................................................................................................33
FT52 - Unders & Overs.............................................................................................................................................34

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INSTALLATION MANUAL FITNESS TRACK
20 September 2016
FITNESS TRACK
PREPARE THE SITE
Fitness Track equipment is normally designed for installation on a flat level surface so you should ensure
that the proposed area is prepared correctly.
Check that the site is clear of underground power and services before you commence digging.
If soft-fall surfacing is to be used below the equipment, for ease of installation do not put the soft-fall
surfacing in until after the equipment has been installed. Ensure that you allow for the required soft-fall
depth when excavating the site. Any excavation should take place prior to commencing installation of the
equipment.
Before you commence installation you should lay out the equipment and ensure that you have all items
detailed on the materials or packing list.
EQUIPMENT REQUIRED FOR INSTALLATION
1. Ratchet (or socket set) with ½” driver
2. Ratchet (or socket set) with 3/8” driver
3. Cordless Drill
4. Shovel for digging holes (preferably long handled)
5. If digging in hard ground you may need a 300mm auger and a crow bar
6. Spirit level
7. ‘G’ clamps (for holding items in place prior to bolting)
8. Stringline
9. ‘Vice-grip’ pliers (for closing ‘S’ hooks)
10. An axe (for cutting tree roots if they are in the way)
11. Concrete for footings
12. Bricks/pavers (to provide stability below ground where required)
13. A basic first aid kit for emergencies
14. ‘Occupational Health and Safety’ plan and procedures if applicable
SECURING THE SITE WHILE WORK IS IN PROGRESS
You should ensure that the work site is clearly defined by some sort of barrier or temporary fence to
ensure that children or onlookers are not in danger of injury while you work. The concrete footings
will need at least 24 hours to set so a barrier or fence will keep people off the equipment until it is
ready to be used and until adequate soft-fall surfacing has been installed.

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INSTALLATION MANUAL FITNESS TRACK
20 September 2016
PREPARATION FOR INSTALLATION
1. Before you commence installation you should lay out the equipment and ensure that you
have all items detailed on the materials or packing list. (Each upright is numbered at the
base in accordance with the numbering on the plan.)
2. Group the uprights for each piece of equipment together, along with the attaching items.
3. Layout the equipment roughly on the ground to ensure that it fits within the prepared
area.
4. Determine the proposed finished surface level and use a string line to set this level. This
will help in ensuring that the items are set at their correct height above ground level.
CONCRETE FOOTINGS
Concrete should be used on all items in the ground as per the diagram.
Generally the footing should be 300mm x 300mm x 500mm (deep) with
a tapered top so that water won’t pool around the upright. Where loose
fill surfacing is used ensure that the concrete is 400mm below the
finished surface level or that the footing is effectively covered by items
of equipment in such a way that they do not present a hazard. (Note: If
the ground is soft or likely to be subject to settling it is best to use an
additional 100mm of concrete on the footing below the upright.) Most
legs will extend around 800mm below ground but may vary so the depth
in ground should be determined by the height of the upright above
finished ground level as indicated in these instructions.
FASTENERS
fAST
Tri-lobe
Bolt
Torx
Bolt
Cap Nut
T
Nut
Cup Head
Bolt
Tech Screw
Security Cap M6
For Tech Screws
S Hook
Tri-lobe
Driver
Torx
Driver

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INSTALLATION MANUAL FITNESS TRACK
20 September 2016
FLANGES & RAILS
Most of the rails connect to the uprights using moulded plastic
flanges. These flanges will be included in the bolt packs.
Connect the flanges to each end of the component to be
attached to an upright using a tech screw. A security cap
should be used with each tech screw as shown, fitting the
base to the screw before fastening. The tech screw is
inserted through the dimpled hole in the side of the flange
and into the steel pipe using a power drill and the tech screw
driver supplied. Once secure, the top of the security cap
should be securely fastened. Each flange is then connected to the uprights using two 20mm tri-
lobes (in some instances 25mm tri-lobes will be supplied and can be used).
The flanges can be fastened to the rails prior to attaching to the uprights. In some cases it may be
easier to loosely fit the flanges in place on the rails then fasten the flanges to the upright. Once
satisfied that the uprights are square the flanges can be secured to the component using tech
screws.
Where rails are used to determine the distance between platforms a tape measure should also be
used to allow for movement in the flanges if they are not yet secured.

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INSTALLATION MANUAL FITNESS TRACK
20 September 2016
FT01A –CHIN UP BAR ‘A’
Using the 1200mm length chin up rails
(5274) as a guide to determine the distance
between uprights, dig holes for the uprights.
After placing the uprights in the holes and
ensuring that their depth is correct (so that
the height of the upright which extends
above the finished ground level is as
indicated in the drawing), attach the flanges
to the rails and fasten the chin up bars to
the uprights. After ensuring that the
uprights are vertical, the rails horizontal and
the bolts are tightened, concrete the
uprights into the ground. Fill the top of the
holes with soil, packing firmly.
FT01B –CHIN UP BAR ‘B’
Install following the same instructions as FT01a above.

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INSTALLATION MANUAL FITNESS TRACK
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FT02 –LOG WALL
Using the 1650mm length rails (5576 or 5575) as a
guide to determine the distance between uprights,
dig holes for the uprights. After placing the uprights
in the holes and ensuring that their depth is correct
(so that the height of the upright which extends
above the finished ground level is as indicated in the
drawing), attach the flanges to the rails and fasten
the rails to the uprights. After ensuring that the
uprights are vertical, the rails horizontal and the bolts
are tightened, concrete the uprights into the ground.
Fill the top of the holes with soil, packing firmly.
FT-02-1
5576
5575
FT-02-1

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INSTALLATION MANUAL FITNESS TRACK
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FT03 & FT36 –ROPE SWING / ROPE CLIMBER
The frame is best assembled prior to installation. Assemble the frame while laid on the ground then
roll into the upright position. The uprights (6112) are fastened to the top bar (FT-15-1) using
25mm tri-lobe bolts. Where tie bars (5896) are used they are fastened to the uprights using a
130mm threaded stud with stainless steel cap nuts on both ends. Use the frame in its upright
position to determine the correct hole position and dig the holes. Lower the frame into the holes,
ensuring that the top bar is level and at the correct height (2.5m above the finished surface level).
After ensuring that all bolts are tightened, concrete the uprights into the ground. Fill the top of the
holes with soil, packing firmly.
Dig another hole for each knotted rope to a depth that allows them to hang straight down. Concrete
the anchors at the base of the ropes into the ground so that they hang virtually straight.
FT36
FT-15-1
6112
5369
2500
FT03
5896
2500

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INSTALLATION MANUAL FITNESS TRACK
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FT04 –LEAP FROG
Fasten steppers to the uprights using 17mm tri-lobes.
Dig holes for each upright. The leap frogs can be
arranged in varying configurations but the distance
between each should be uniform. Our recommended
distance between each post is approximately 4 metres.
After placing the uprights in the holes and ensuring that
their depth is correct (so that the top of the leap frog
extends 650mm above the finished ground level as
indicated in the drawing), ensure that the uprights are
vertical and concrete them into the ground. Fill the top
of the holes with soil, packing firmly.

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INSTALLATION MANUAL FITNESS TRACK
20 September 2016
FT05 –MONKEY BARS
Using the Monkey Bar (5053) as a guide to determine the distance between uprights, dig holes for
the 4 uprights. Place the uprights in the holes and ensuring that their depth is correct (so that the
height of the upright which extends above the finished ground level is as indicated in the drawing).
Attach the flanges to the Monkey Bar, lift into place and fasten to the uprights. Attach flanges to the
rungs (5078) and fasten to the uprights. Attach and the support legs (5836) using a tap-tight tri-
lobe bolt.
After ensuring that the uprights are vertical, the rails horizontal and the bolts are tightened,
concrete the uprights into the ground. Fill the top of the holes with soil, packing firmly.
FT-05-1
5053
5836
5078

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INSTALLATION MANUAL FITNESS TRACK
20 September 2016
FT06 –OBSTACLE FRAME
Using the 1650mm length rails (5576 or 5575) as a guide to
determine the distance between uprights, dig
holes for the uprights. After
placing the uprights in the holes
and ensuring that their depth is
correct (so that the height of the
upright which extends above the
finished ground level is as
indicated in the drawing), attach
the flanges to the rails and
fasten the rails to the uprights.
After ensuring that the uprights
are vertical, the rails horizontal
and the bolts are tightened,
concrete the uprights into the
ground. Fill the top of the holes
with soil, packing firmly.
FT07 –SIT UP BOARD
The Sit Up Board comes in 3 versions, with the
angle of the boards being set at either 10, 15 or
20 degrees.
Assemble the Sit Up Board completely (prior to
digging any holes in the ground), fastening the
boards (6213) to the frames using 20mm tri-
lobe bolts. Use the completed item to mark the
location for the holes in the ground. The depth
of the holes should allow for the lower end of the
Sit Up Board to sit approximately 100mm above
the finished ground level.
After ensuring that the bolts are tightened,
lower the legs on the Sit Up Rack into the holes.
Make sure that the frames are vertical then
concrete the legs into the ground. Fill the top of
the holes with soil, packing firmly.
FT-06-1
FT-06-2
FT-06-3
5576
6213
6515 (10 deg)
6517 (15 deg)
6519 (20 deg)
6514 (10 deg)
6516 (15 deg)
6518 (20 deg)
100 (all
angles)
600 (10 deg)
715 (15 deg)
830 (20 deg)

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INSTALLATION MANUAL FITNESS TRACK
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FT08 –CHAIN NET & FRAME
Using the 1650mm length rails (FT-08-2 or
5575) as a guide to determine the distance
between uprights, dig holes for the uprights.
After placing the uprights in the holes and
ensuring that their depth is correct (so that
the height of the upright which extends
above the finished ground level is as
indicated in the drawing), attach the flanges
to the rails and fasten the rails to the
uprights.
Dig a trench for the anchor (FT-08-3)
allowing for the chain to be on
approximately a 45 degree angle with the
top of the anchor being at least 300mm
below the finished ground level.
Attach the chains (FT-08-4) to the top rail
(FT-08-2) and to the anchor (FT-08-3) using
8mm ‘S’ hooks. Ensure the ‘S’ hooks are
fully closed using vice-grips.
After ensuring that the uprights are vertical,
the rails horizontal and the bolts are
tightened, concrete the uprights into the
ground. Fill the top of the holes with soil,
packing firmly.

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INSTALLATION MANUAL FITNESS TRACK
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FT09 –PARALLEL BARS
Assemble the parallel bars on the ground
(prior to digging any holes), inserting the
legs (FT-09-2) into the top bars (FT-09-1)
and fastening with ‘tap tight’ (self tapping)
tri-lobe bolts.
Use the legs to mark the correct position
then dig the holes in the ground, ensuring
that their depth is correct (so that the height
of the top of the Parallel Bars is 1200mm
above the finished ground level as indicated
in the drawing.) The two Parallel bars should
be positioned between 500mm and 600mm
apart. After ensuring that the legs are
vertical, the top rails horizontal and the bolts
are tightened, concrete the legs into the
ground. Fill the top of the holes with soil,
packing firmly.
FT-09-1
FT-09-2

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INSTALLATION MANUAL FITNESS TRACK
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FT10 –HURDLES
Assemble the hurdles on the ground (prior
to digging any holes), connecting the top
beams (FT-10-1) to the uprights (FT-10-2)
using 140mm cup head bolts and cap nuts.
Use the legs to mark the correct position
then dig the holes in the ground, ensuring
that their depth is correct (so that the
height of the top beams are 500mm above
the finished ground level as indicated in
the drawing.) Each hurdle should be set at
a uniform distance of at least 3 metres
apart.
After ensuring that the legs are vertical,
the top beams horizontal and the bolts are
tightened, concrete the uprights into the
ground. Fill the top of the holes with soil, packing firmly.
FT11A –BALANCE WALKERS ‘A’
Lay the top beams (FT-11A-1, 2 & 3) on the ground with each beam running at 90 degrees from the
end of the last. Determine the position of the uprights by locating the holes in the top beams and
dig the holes in the ground.
After placing the uprights in the holes and ensuring that their depth is correct (so that the height of
the upright which extends above the finished ground level is as indicated in the drawing), fasten the
top beams to the uprights using 140mm cup head bolts and cap nuts. After ensuring that the legs
are vertical, the top beams horizontal and the bolts are tightened, concrete the uprights into the
ground. Fill the top of the holes with soil, packing firmly.
FT-10-1
FT-10-2
FT-11A-1
FT-11A-5
FT-11A-4
FT-11A-2
FT-11A-3
FT-11A-1
FT-11A-6

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INSTALLATION MANUAL FITNESS TRACK
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FT11B –BALANCE WALKERS ‘B’
Install these items in the same way as
‘Hurdles’ (above) except that each beam is
free standing. Two of the balance beams
should be set at 300mm above finished
ground level, two at 500mm, and the last will
incline from 300mm to 500mm.
FT12 –SWINGING BALANCE BEAM
Using the handrails (5254) and the ‘end frame joiners’ (5599) as a guide to determine the distance
between uprights, dig holes for the uprights. After
placing the uprights in the holes and ensuring that
their depth is correct (so that the height of the
upright which extends 1400mm above the finished
ground level as indicated in the drawing), attach
the flanges to the rails and fasten the rails to the
uprights. Fasten the ‘end frame joiners’ to the
uprights using 17mm tri-lobe bolts. After ensuring
that the uprights are vertical, the rails horizontal
and the bolts are tightened, concrete the uprights
into the ground. Fill the top of the holes with soil,
packing firmly.
Connect the balance beam to the chains and the
end brackets using 8mm ‘S’ hooks. Ensure the ‘S’
hooks are fully closed using vice-grips. Attach the
brackets to the end frame joiner using stainless
steel cap nuts and 30mm cup head bolts.

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INSTALLATION MANUAL FITNESS TRACK
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FT13 –STEP UP
Assemble the Step Up on the ground (prior to digging any holes), connecting the top beam (FT-13-
2) to the uprights (FT-13-1) using 140mm cup head bolts and cap nuts.
Use the legs to mark the correct position then dig the holes in the ground, ensuring that their depth
is correct (so that the height of the top beam is 300mm above the finished ground level as indicated
in the drawing.) After ensuring that the legs are vertical, the top beam horizontal and the bolts are
tightened, concrete the uprights into the ground. Fill the
top of the holes with soil, packing firmly.
FT14 –ROMAN TRIANGLES
Using the Roman Triangles (5073) as a guide
to determine the distance between uprights,
dig holes for the 4 uprights. Place the uprights
in the holes and ensuring that their depth is
correct (so that the height of the upright which
extends above the finished ground level is as
indicated in the drawing).
Attach the flanges to the Roman Triangles, lift
into place and fasten to the uprights. Attach
flanges to the rungs (5078) and fasten to the
uprights. After ensuring that the uprights are
vertical, the top bar horizontal and the bolts
are tightened, concrete the uprights into the
ground. Fill the top of the holes with soil,
packing firmly.
5073
FT-14-1
5078

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INSTALLATION MANUAL FITNESS TRACK
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FT15 –FIREMAN’S POLE
The frame is best assembled prior to
installation. Assemble the frame while laid on
the ground then roll into the upright position.
The uprights (6112) are fastened to the top bar
(FT-15-1) using 25mm tri-lobe bolts. The tie
bars (5896) are fastened to the uprights using
a 130mm threaded stud with stainless steel cap
nuts on both ends. Use the frame in its
upright position to determine the correct
hole position and dig the holes. Lower the
frame into the holes, ensuring that the top
bar is level and at the correct height (2.8m
above the finished surface level). After
ensuring that all bolts are tightened,
concrete the uprights into the ground. Fill
the top of the holes with soil, packing firmly.
Dig another hole for each fireman’s pole to a
depth that allows them to hang straight
down. Attach the top of the fireman’s poles
to the top beam using 8mm ‘S’ hooks.
Ensure the ‘S’ hooks are fully closed using
vice-grips.
Concrete the chains at the base of the poles into the ground so that they hang virtually straight
FT16 –ROLL OVER BAR
Assemble the Roll Over Bar on the ground (prior to digging any holes), inserting the legs (6016) into
the top bar (FT-16-1) and fastening with ‘tap tight’ tri-lobe bolts.
Use the legs to mark the correct position then dig the holes in the ground, ensuring that their depth
is correct (so that the height of the top of the Roll Over Bar is 900mm above the finished ground
level as indicated in the drawing.) After ensuring that the legs are vertical, the top rail horizontal
and the bolts are tightened, concrete the legs into the ground. Fill the top of the holes with soil,
packing firmly.
FT-15-1
5896
6112
5361
FT-
6016

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INSTALLATION MANUAL FITNESS TRACK
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FT17 –ACHILLES STRETCH
Dig a hole in the ground, ensuring that the depth is correct (so that the height
of the top of the post is 1800mm above the finished ground level as indicated
in the drawing.) After ensuring that the post is vertical concrete the legs into
the ground. Fill the top of the holes with soil, packing firmly.
FT18 –PUSH UP BARS
Using the 1200mm length push up rails (5274) as a guide to determine the distance between
uprights, dig holes for the uprights. After placing the uprights in the holes and ensuring that their
depth is correct (so that the height of the upright which extends above the finished ground level is
as indicated in the drawing), attach the flanges to the rails and fasten the rails to the uprights. After
ensuring that the uprights are vertical, the rails horizontal and the bolts are tightened, concrete the
uprights into the ground. Fill the top of the holes with soil, packing firmly.
FT-17
5274
FT-18-1
FT-18-2
FT-18-3

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INSTALLATION MANUAL FITNESS TRACK
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FT19 –VAULT BAR
Assemble the Vault Bar on the ground (prior to digging any holes), inserting the leg (FT-09-2) into
the top bar (FT-19-1) and fastening with a ‘tap tight’ tri-lobe.
Use the legs to mark the correct position then dig the holes in the ground, ensuring that their depth
is correct (so that the
height of the top of the
Vault Bars is 1200mm
above the finished
ground level as indicated
in the drawing.) After
ensuring that the legs
are vertical and the bolt
is tightened, concrete the
legs into the ground. Fill
the top of the holes with
soil, packing firmly.
FT20 –LEG LIFT BAR
Dig a hole in the ground, ensuring that the depth is correct (so that the height
of the top of the post is 2200mm above the finished ground level as indicated in
the drawing.) After ensuring that the post is vertical concrete the legs into the
ground. Fill the top of the holes with soil, packing firmly.
FT-19-
1
FT-09-
2
FT-20-
1

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INSTALLATION MANUAL FITNESS TRACK
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FT23 –BURMESE BRIDGE
Using the handrails (5011) and the ‘end frame joiners’ (5599) as a guide to determine the distance
between uprights, dig holes for the uprights. After placing the uprights in the holes and ensuring
that their depth is correct (so that the height of the upright which extends 1400mm above the
finished ground level as indicated in the drawing), attach the flanges to the rails and fasten the rails
to the uprights. Fasten the ‘end frame joiners’ using 17mm tri-lobe bolts. After ensuring that the
uprights are vertical, the rails horizontal and the bolts are tightened, concrete the uprights into the
ground. Fill the top of the holes with soil, packing firmly.
Attach each bracket (S5191) to the end frame joiners using stainless steel cap nuts and 30mm cup
head bolts. Attach the chains (5883) to the brackets and to the handrails using 8mm ‘S’ hooks.
Ensure the ‘S’ hooks are fully closed using vice-grips.