Forpark Australia NINJA COURSE User manual

NINJA COURSE
INSTALLATION MANUAL

NINJA COURSE
INSTALLATION MANUAL ESSENTIALS & ESSENTIALS TIMBER
19 October 2022
FORPARK AUSTRALIA INSTALLATION MANUAL
INSTALLATION MANUAL ELEVATE
19 October 2022
Congratulations on selecting Forpark Australia equipment for your Ninja Course.
This manual provides you with easy-to-follow instructions that will enable you to install the equipment correctly.
Installing your own Ninja Course can be a simple and rewarding task and it is satisfying to be able to stand back
when the job is finished and say “we did that!”
As a quality assured company our equipment complies with the following standards for play equipment as a
minimum, to ensure the safety of your children.
•AS 4685:2021, Parts 1 – 6, Playground equipment (Safety requirements and test methods)
•AS 4422:2016 Playground surfacing – Specifications, requirements and test method
•AS 4685.0.2017 Playgrounds and playground equipment – Part 1: Development, slide installation,
inspection, maintenance and operation
You may be interested to know that Forpark Australia is a family-owned Australian company and that we are the
largest in-house manufacturer of playground equipment in Australia.
We have been manufacturing playground equipment since 1979 and provide you with the benefit of the
knowledge and experience that we have developed over these years.
This installation manual should be kept for future reference and to help you with your maintenance program.
A recommended maintenance schedule is provided at the rear of this manual.
Good luck with your installation.
Darryl G. Hansen
Managing Director

NINJA COURSE
INSTALLATION MANUAL ESSENTIALS & ESSENTIALS TIMBER
19 October 2022
FORPARK AUSTRALIA INSTALLATION MANUAL
INSTALLATION MANUAL ELEVATE
19 October 2022
Contents
Prepare the site ............................................................................. 1
Equipment required for installation....................................... 1
Check the contents of the crate.............................................2
Securing the site while work is in progress.........................2
Preparation for installation........................................................2
Reading the plans.........................................................................3
Installation.......................................................................................4
Uprights, Components and Fasteners..................................4
Flanges .............................................................................................5
Chain Housing Connections....................................................5
Determining Spacing between Uprights .............................6
Concrete Footings.......................................................................6
Ropes or Chains in ground.......................................................6
Loctite...............................................................................................6
Fasteners ......................................................................................... 7
Installation – Components.......................................................9
Arched Cargo Net ...................................................................9
Balance Beam...........................................................................9
Bar Hop.......................................................................................9
Cargo Net...................................................................................9
Chain Traverse....................................................................... 10
Combo Grips Traverse ....................................................... 10
Finish Bell ................................................................................ 10
Grip Traverse.......................................................................... 10
Handle Traverse.................................................................... 10
Horizontal Cargo Net .......................................................... 11
Monkey Bars............................................................................ 11
Monkey Spin Traverse ......................................................... 11
Mountain Ascent ...................................................................12
Pad..............................................................................................13
Peg Diagonal Traverse ........................................................13
Peg Straight Traverse...........................................................13
Platform ....................................................................................14
Pommel Hop ..........................................................................14
Pommel Traverse..................................................................14
Rock Wall .................................................................................15
Rung 300..................................................................................15
Swing Traverse.......................................................................15
Vertical Climbing Wall Double .........................................16
Vertical Climbing Wall Single............................................16
Vertical Spider Wall...............................................................17
Warped Wall...........................................................................17
Sign Custom............................................................................18
Start, Finish Signs...................................................................19
Before Leaving the Site ........................................................... 20
Safety and Maintenance Inspections ................................. 20
Routine Visual Inspection....................................................... 20

NINJA COURSE
INSTALLATION MANUAL ESSENTIALS & ESSENTIALS TIMBER
19 October 2022
FORPARK AUSTRALIA INSTALLATION MANUAL
INSTALLATION MANUAL ELEVATE
19 October 2022
Prepare the site
Before any installation you should be familiar with the requirements of AS 4685 (Parts 1-6) – 2021 “Playground
equipment – safety requirements and test methods” (particularly relating to fall zone requirements), AS 4422:2016
“Playground surfacing – specifications, requirements and test method” (relating to the type and depth of your soft-
fall surfacing), and AS 4685.0:2017 “Playgrounds and playground equipment – development, installation,
maintenance and operation” (dealing with your site requirements and ongoing maintenance).
If you require advice, talk to one of our consultants. Some important things to remember are as follows:
1. Ninja Course equipment is normally designed for installation on a flat level surface so you should
ensure that your play area is prepared correctly.
2. Check that the site is clear of underground power and services before you commence digging.
3. Measure the site to ensure that it is large enough to allow for the correct fall zones between the
equipment and the outside of the soft-fall surface, and correct distances between various items of
equipment. If you are unsure of these requirements you should check with your Forpark
representative.
4. 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 before commencing installation of the equipment.
Equipment required for installation
1. Ratchet (or socket set) with ½” driver
2. Ratchet (or socket set) with 3/8” driver
3. 13mm drill bit for drilling platforms
4. Cordless drill
5. Shovel for digging holes (preferably long-handled)
6. If digging in hard ground, you may need a 300mm auger and a crowbar
7. Spirit level
8. ‘G’ clamps (for holding items in place before bolting)
9. String line
10. Wheelbarrow
11. ‘Vice-grip’ pliers (for closing ‘S’ hooks)
12. An axe (for cutting tree roots if they are in the way)
13. Concrete for footings
14. Bricks/pavers (to provide stability below ground where required)
15. Scaffolding/platform ladder/s where necessary
16. A basic first aid kit for emergencies
17. ‘Occupational Health and Safety’ plan and procedures if applicable

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
2
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Check the contents of the crate
In addition to the equipment itself, you should have the following:
1. Plans of the Ninja Course
2. Materials or packing list
3. Tri-lobe driver (driver with a rounded triangular head which fits onto your ½” driver)
4. Hex head Allen keys (where required)
5. Torx Driver (driver with a star-shaped head that fits onto your 3/8” driver)
6. Tech Screw Driver
7. Nuts and bolts, etc.
8. Touch up paint
9. Loctite
Securing the site while work is in progress
You should ensure that the worksite is clearly defined by some sort of barrier or a 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.
Preparation for installation
1. Before you commence installation, you should familiarise yourself with the general instructions found
on pages 3 to 8 of this manual. The various individual items of your equipment will be covered later in
the manual.
2. Once ready to commence installation you should lay out the equipment and ensure that you have all
items detailed on the materials or packing list.
3. Group the numbered uprights, in order of their installation so that they are readily available as required
(see “Reading Plans”).
4. Lay the equipment out roughly on the ground to ensure that it fits within the prepared area and that all
required fall zones are met.
5. Determine the proposed finished surface level and use a string line to set this level. This will help in
ensuring that the platforms and other items are set at their correct height above ground level.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
3
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Reading the plans
You have been supplied with two types of plans, one showing the actual layout of the equipment and the other
showing the position of the uprights. (See below for examples of both plans.)
The upright plan contains several squares representing each upright and their locations corresponding with the
uprights in the equipment layout plan. The figures inside each square represent the upright number and the height
of that upright, e.g. upright 1 (below) is 3.0m in length. The letters on the outside of each square provide the
orientation of each upright in relation to the items to be attached. The corresponding upright number is marked
on the bottom of each upright supplied (along with some other details as shown below). The upright number is
always marked on side ‘B’. When standing at the base of the upright and holding it in a horizontal position with
side ‘B’ facing up, you will rotate the upright counter-clockwise to bring side ‘C’ to the face-up position and so
forth.
Upright Plan (as though looking
down on the uprights from
above)
Equipment Layout Plan
(As though looking down from
above)
Upright Markings
(Base of each upright, always on side
‘B’)
STRUCTURE
IDENTIFIER
UPRIGHT
NUMBER
COLOUR
IDENTIFIER

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
4
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Installation
Uprights, Components and Fasteners
Uprights are pre-drilled with holes corresponding to the components to be attached. Aluminium uprights have a
threaded insert fitted to each hole.
Each upright has a black plastic 100mm x 100mm cap inserted in the top and in the base. If the base caps have not
been inserted already, they will be supplied loose and should be inserted into the bottom of each upright before
installing.
Uprights should normally be installed to a depth of 800mm below the finished surface level. (If rubber surfacing
has been specified the uprights may have been cut to allow 600mm below finished surface level.) Make sure that
you allow for the safety soft-fall surfacing when digging your holes, i.e., if the upright needs to be buried 800mm
below finished surface level, and you have already excavated 300mm for soft-fall, the holes only needs to be
500mm deep. (Note: If the ground is soft or likely to be subject to settling it is best to dig the holes an additional
100mm deep and lay a 100mm thick footing using rapid set concrete prior to inserting the uprights.)
Choose one of the components as a starting point on the structure and mark the uprights position. This could be
in the centre of the structure to enable teams to work outwards in both directions at the same time. Before
commencing the installation ensure that you have allowed for the correct fall zone between the equipment and
the edge of the soft-fall surface.
Place the uprights into the holes, ensuring that the identification numbers on the base of the uprights match the
identification numbers on the upright plan. It may help to place a frame on the ground as a guide to enable you to
work out the correct positioning of the upright holes. It is important that its height in relation to the finished
ground surface is correct.
Once the uprights are in the holes at the correct height, lift the frames into place and fasten each frame to the
upright by using 20mm tri-lobes. Refer to the ‘upright plan’ to determine the correct orientation of each upright. It
is important to make sure that the components are level and at the correct height, and the uprights vertical.
Once satisfied that the components are level and the uprights vertical, concrete the uprights and fill the holes,
packing the soil firmly.
Note: Occasionally, due to human error, some holes in the uprights may be missed. Should this happen you can
drill the holes on site. (You may need to check with your Forpark office first if unsure of the exact hole location.)
For aluminium uprights a 13.5mm hole should be drilled and a threaded insert fitted.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
5
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Flanges
Many items connect to the uprights using moulded plastic flanges. These flanges
will be included in the bolt packs. Square flanges are used on uprights that are
square to the face of the platform.
In many cases it may be easier to loosely fit the flanges in place on the component
then fasten the flanges to the upright. Each flange attaches to the upright using two
20mm tri-lobes (in some instances 25mm tri-lobes will be supplied and can be used).
Once satisfied that the uprights are correctly positioned and square, each flange can
be secured to the component 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.
Before securing each item ensure that the spacing between uprights and
platforms is correct as detailed below.
Chain Housing Connections
Several items have chains that attach to a top bar or rail. In these cases,
the top bar or rail has chain housings connected. The chain should be
inserted into the housing as far as it will go. An 8mm Torx bolt is then
inserted into the hole in the housing, through the end link of chain,
securing the chain in place. Make sure a small amount of ‘Loctite’ is
applied to the thread before tightening.
SQUARE FLANGE

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
6
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Determining Spacing between Uprights
Tape measure should also be used to check distances, allowing for movement in the flanges if they are not yet
secured. Alternatively, a component (or components) laid on the ground could be used as spacers. The distances
between most components (centre of uprights) are – width 1400mm and length 3100mm.
Concrete Footings
We recommend that concrete be used on all uprights and items in the ground
as per the diagram. The footings on uprights should be approximately 300mm x
300mm x 400mm (deep). Attachment components will generally only go
600mm below finished surface level and a smaller footing will be sufficient
(approx. 300mm x 300mm x 300mm). All footings should have a tapered top so
that water won’t pool around the upright. Where loose fill surfacing is used
ensure that the concrete is at least 300mm 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. This may need to set before placing the upright in place.)
Forpark recommends General Purpose Concrete. This is a concrete with a
compressive strength of 20MPa (at 28 days) or higher.
The concrete used in playground footings should only be mixed and/or worked by a suitably experienced person
following supplier/manufacturer’s instructions.
Freestanding items may require a larger footing as detailed individually.
Forpark trims 200mm off the square 100 uprights, in structures only, when a job is to be installed in rubber, this is
done to make the installation easier as the post and footing do not need to be 800mm below FGL (600mm is
sufficient).
The footing sizes are to remain the same as standard but will now be a 200mm higher up the post. There will be
no negative effects to the structural integrity of the structure when the posts are installed in this manner.
Ropes or Chains in ground
Hang the rope or chain, mark and dig hole in ground approx. 700mm
below finished ground level and 300mm x 300mm wide. Attach anchor
with S hook, lower in the hole and concrete (footing approx. 300mm x
300mm x 400mm).
Loctite
‘Loctite’ is provided in each bolt pack. This should be used on any bolt used on items subject to movement or
vibration.
Where ‘Loctite’ is required only one to two drops need be applied to the thread of the bolt, immediately before
inserting into the nut and tightening.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
7
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Fasteners
All holes in aluminium uprights require nutserts (threaded inserts fitted in the holes). Regular tri-lobes are used
when connecting to ‘T’ Nuts, Cap Nuts and nutserts.
In some instances, tri-lobe bolts will be replaced with Torx bolts. Both will do the same job. This will be
particularly common where stainless steel fasteners are used.
The commonly used fasteners are shown below.
Tri-lobe
Torx Bolt
(Stainless Steel)
Counter Sunk
Bolt
Cup Head Bolt
Cap Nut
T Nut
S Hook
Washer
Plastic Cap 100x100
(For uprights)
Tri-lobe Driver
Allen Key
Security Cap M10
Security Cap M6
For Tech Screws
Torx Driver

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
8
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Please note that all S-Hooks should be fitted with the small loop attaching to the chain, and the large loop
attaching to the connecting item.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
9
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Installation – Components
Arched Cargo Net
The top of the top bars to be 2150mm for junior and
2350mm for senior from finished ground level.
Attach top bars to uprights with Trilobes 20mm. Rail
to top bars with standard flange connection. Top
and bottom rope chains to rail and to steel flanges
with standard chain housing connection.
Balance Beam
Legs are 600mm in ground.
Bar Hop
The top of Bar Hop 300 to be 325mm and Bar Hop 700 725mm from
finished ground level. Legs are 600mm in ground.
Cargo Net
Check plan for item height. Attach top bars to uprights with Trilobes 20mm.
Rail to top bars and rail to uprights with standard flange connection. Top and
bottom rope chains to rails with standard chain housing connection.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
10
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Chain Traverse
Requires platforms at each end.
The top of the frame to be 2150mm
for junior and 2350mm for senior
from finished ground level.
Attach frame to uprights with
Trilobes 20mm. Top and bottom
chains to frame and to brackets
with standard chain housing
connection.
Brackets to platforms with Trilobes 20mm.
Combo Grips Traverse
Check plan for item height. Attach frame to
uprights with Trilobes 20mm. Chains to frame
with standard chain housing connection.
Finish Bell
The Finish Bell if in use, is attached on top of
one of the uprights, instead of plastic cap.
Check the plan.
Grip Traverse
Check plan for item height. Join chains to frame
with standard chain housing connection.
Attach frame to uprights with Trilobes 20mm.
Handle Traverse
Check plan for item height. Attach frame to uprights
with Trilobes 20mm. Chains of ropes to frame with
standard chain housing connection.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
11
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Horizontal Cargo Net
Requires platforms at each end.
Chains of ropes to brackets with standard chain housing connection.
Brackets to platforms with Trilobes 20mm.
Monkey Bars
Check plan for item height. Attach frame to uprights with
Trilobes 20mm.
Monkey Spin Traverse
Check plan for item height. Attach frame to uprights with
Trilobes 20mm.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
12
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Mountain Ascent
Place the uprights on 1135mm square, with 2 of shorter uprights placed in
diagonal.
Check plan for positioning.
Assemble the platform by joining the 4 sections with Trilobe 25mm, nut and
security caps.
Attach 4 of plastic and steel braces as shown on the circle opening with Trilobe
30mm, nut and security caps.
Attach top rail to the long uprights with Trilobes 20mm and
chain to rail with standard chain housing connection. Mark
the place of the hole in ground for the chain anchor, in the
equal distance from uprights and secure as per “Ropes and
Chains in Ground” on page 6.
There are 3 sides above platform with safety panels. Each
aly board is attached to upper bracket with Trilobes 20mm,
then to lower spacer rail with Trilobes 20mm (cover the
access hole with cap plastic 20Nb.
Safety panels are attached to platform with Trilobes 20mm, from
platform side.
There is one lower spacer rail with no holes for aly boards. This one
is to be attached to the platform on the rungs side.
Use standard flange connection to attach 6 rungs.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
13
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Pad
Assemble parts of the pad as
shown. Check the plan for the
place and orientation of the holes
in ground.
Dig 600x600x600 holes, position
the pads and concrete.
Peg Diagonal Traverse
Screw the plastic balls to the bar
using Screw Post Torx But 14GX2
and lug the hole with cap plastic
15Nb.
Check plan for item height. Bolt to
uprights with Trilobes 20mm.
Peg Straight Traverse
Screw the plastic balls to
the bar using Screw Post
Torx But 14GX2 and lug the
hole with cap plastic 15Nb.
Check plan for item height.
Bolt to uprights with
Trilobes 20mm.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
14
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Platform
The top of the platform to be 300mm from finished ground level. Attach to
uprights with Trilobes 20mm.
Pommel
Hop
The top of Pommel
Hop 300 to be
300mm and
Pommel Hop 700
to be 700mm from
finished ground
level. Legs are 800mm in ground.
Use Trilobes 17mm for joining first the bracket to Pommel
and then the bracket to upright.
Pommel Traverse
The top of the frame to be
2550mm for junior and
2750mm for senior from
finished ground level.
Attach frame to uprights with
Trilobes 20mm.
Mark the place of the holes in
ground for the anchors, by
hanging pommels vertical
and secure as per “Ropes and
Chains in Ground” on page 6.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
15
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Rock Wall
Attach the supporting vertical bars to the horizontal top and bottom
ones and then the panels to the frame with Trilobes 20mm.
Rise and attach to uprights with Trilobes 20mm.
Rung 300
The top of the rung to be 300mm from finished ground level. Attach to uprights
with Trilobes 20mm.
Swing Traverse
Join chain ends of ropes to frame with standard chain housing
connection.
Check plan for item height. Attach frame to uprights with
Trilobes 20mm.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
16
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Vertical Climbing Wall Double
Attach horizontal bars to uprights with Trilobes 20mm.
Join chain ends of ropes to top bars and flanges with standard chain
housing connection. Bolt flanges to uprights with Trilobes 20mm.
Vertical Climbing Wall Single
Join chain ends of ropes to rungs with standard chain housing connection.
Use standard flange connection to attach rungs to uprights.

FORPARK AUSTRALIA | www.forparkaust.com.au
INSTALLATION MANUAL ELEVATE
19 October 2022
17
FORPARK AUSTRALIA INSTALLATION MANUAL
NINJA COURSE
Vertical Spider Wall
Place the uprights on 800mm
square and 470x800mm as
shown.
Attach the platform (Elevate) to
uprights.
Attach pair of handgrip stripes to
top of the panels, using 6mm
Post Torx bolts and Cap Nuts.
Then, single handgrip stripes
using 6mm Post Torx bolts and T
Nuts.
Attach the panels to uprights with
B2 brackets, using Trilobes 17 and
25, Security Caps and M10 nuts.
Use standard flange connection
to attach rungs to uprights.
Bolt The brackets for the safety
panela to uprights with Trilobes
20mm, then the Aly boards to the
brackets with Trilobes 20mm and
Aly boards to platform with
Trilobes 20mm from the platform
side.
Warped Wall
Place the uprights on 970mm
square as shown.
Attach the platform (Essential)
to uprights. Junior to be
2000mm and Senior 2600mm
from finished ground level.
Use standard flange
connection to attach rungs to
uprights.