Playcore NAVIGATOR Series User manual

Issued/Revised:
SHEET 1 OF 5
07/05/12
BT402 NORTH STAR
Play Systems
1-866-814-8697 bigtoys.com
Parts List
PART NUMBERQTYDESCRIPTION
BT4641
INCLINED WALL
BT4761
NAVICLIMB INVERTED
BT4681TWISTED TRIDENT
4024871
UPRIGHT 1
4024891
UPRIGHT 2
3116341
311349*
2
5" POST TOP COVER
812049*43/8" x 1/2" P.B.H.C.S. w/PATCH
INSTALLATION INSTRUCTIONS:
1. Dig footing holes as shown in Ground Plan. See specific installation sheets for Elevation Views.
2. Refer to specific installation sheets for component attachments, hardware, details, and concrete requirements.
3. Attach 5" Post Top Cover to Uprights using 3/8" x 1/2" P.B.H.C.S. w/Patch. See Detail 612.
4. Plumb and level the entire assembly and tighten all fasteners.
5. After entire discrete unit is assembled pour concrete footings within 4" to the top and taper away from post for water drainage. Allow
to cure at least 48 hours before use. NOTE: Temporary bracing may be required until concrete cures.
6. When the structure is finished and satisfactory, eliminate sharp points and sharp edges (burring) on installed hardware like bolt,
nuts, etc. Install resilient surfacing material within the use zone of play structure in accordance with ASTM specifications F1292
appropriate for the fall height of each structure. Refer to the safety guidelines.
MAINTENANCE PROCEDURE:
Periodically check hardware for tightness, and tighten as necessary. Always check all parts for breakage or wear, and immediately
put equipment out of service until any faulty parts found are repaired or replaced. Also Check all metal parts for rust, paint loss and
touch-up if necessary with paint. Check for welded areas and verify integrity. Check periodically resilient surfacing for appropriate
depth and remove extraneous materials that could cause injury, infection, or disease. Maintain detailed installation, inspection,
maintenance, and repair records for each public-use playground equipment.
Items listed below Hardware Complete line are included with Hardware Complete Number
Warning: During Installation, Hardware And Small Parts Are Choking Hazards For Young Children. Store
Unused Parts Appropriately Until Assembly Is Completed. Once Assembly Is Completed, Remove Any
Unused Parts From The Play Environment And Dispose/Save Them In A Secure Location. Any bolt end
protruding more than two full threads beyond the face of the nut causes risk of clothing entanglement.
Promptly cut-off flush, file smooth, and treat to prevent corrosion.
Unless Otherwise Specified, All Units of Measure are Each
Note: Peen Tee-Nuts and Flatwashers to match radius of pipe after assembly is complete.
Note: Loctite (supplied by others) should be used on any non-patch hardware.
HARDWARE COMPLETE

Issued/Revised:
SHEET 2 OF 5
07/05/12
BT402 NORTH STAR
Play Systems
1-866-814-8697 bigtoys.com
FINISHED ASSEMBLY
NAVICLIMB INVERTED
(BT476)
TWISTED TRIDENT
(BT468)
INCLINED WALL
(BT464)
UPRIGHT 1
(402487)
UPRIGHT 2
(402489)
= INSTALLATION DETAIL
612
5" POST TOP COVER
(311349)

Issued/Revised:
SHEET 3 OF 5
07/05/12
BT402 NORTH STAR
Play Systems
1-866-814-8697 bigtoys.com
PLAN VIEW
TWISTED TRIDENT
(BT468)
INCLINED WALL
(BT464)
UPRIGHT 1
(402487)
UPRIGHT 2
(402489)
NAVICLIMB INVERTED
(BT476)

Issued/Revised:
SHEET 4 OF 5
07/05/12
BT402 NORTH STAR
Play Systems
1-866-814-8697 bigtoys.com
2
3
4
5
6
7
9
8
10
Horizontal Dim.
VerticalDim.
1
FOOTING TABLE
Hole No. Hor. Dim Ver. Dim. Diagonal
1000
218 3/16" 5" 18 7/8"
333 7/8" 28 11/16" 44 3/8"
40
84 11/16" 84 11/16"
599 1/16" 108 11/16" 147 1/16"
655 5/16" 122 1/8" 134 1/16"
775 3/16" 97 15/16" 123 1/2"
80132 11/16" 132 11/16"
975 3/16" 119 7/16" 141 1/8"
10 33 7/8" 188 11/16" 191 11/16"
GROUND PLAN
193 3/8 in
[491.17 cm]
n18 in
[45.72 cm]
TYP.

Issued/Revised:
SHEET 5 OF 5
07/05/12
BT402 NORTH STAR
2
1
34
2
5
1
CM
0
INCH0
10961114815
712 13
4
365
1-866-814-8697 bigtoys.com
612
UPRIGHT
5" POST TOP COVER
(311349)
3/8" x 1/2" P.B.H.C.S.
w/PATCH (812049)

Parts List
PART NUMBER
QTYDESCRIPTION
3090824
14 15/16" CABLE
3082542CABLE
3115391
ANGLE WALL HDPE
3115431
ANGLE WALL
4015491PLAYSHELL
4024152
PLAYSHELL PIPE
3115711
311350*
2
SHROUD
311570*
1
HANDHOLD PACKAGE
402250*
4
PLAYSHELL STOP CASTING ASS'Y
812083*
4
1/4" x 1 1/4" P.B.H.C.S.
817408*41/4" FLAT WASHER (5/8" O.D.)
812052*
21
3/8" x 3/4" P.B.H.C.S. w/PATCH
812051*
2
3/8" x 1 1/4" P.B.H.C.S. w/PATCH
812053*143/8" x 1 1/2" P.B.H.C.S. w/PATCH
812057*
2
3/8" x 2 1/2" P.B.H.C.S. w/PATCH
801051*23/8" x 5 3/4" HEX HEAD BOLT
817410*
41
3/8" FLAT WASHER
817424*
2
3/8" FLAT WASHER (1 1/4" O.D.)
804353*23/8" LOCK NUT
804804*
35
3/8" BARREL NUT
817451*163/4" ID BRONZE BEARING
HARDWARE COMPLETE
Issued/Revised:
SHEET 1 OF 7
03/04/13
BT464 INCLINED CLIMBER
Play Systems
1-866-814-8697 bigtoys.com
Items listed below Hardware Complete line are included with Hardware Complete Number
Warning: During Installation, Hardware And Small Parts Are Choking Hazards For Young Children. Store
Unused Parts Appropriately Until Assembly Is Completed. Once Assembly Is Completed, Remove Any
Unused Parts From The Play Environment And Dispose/Save Them In A Secure Location. Any bolt end
protruding more than two full threads beyond the face of the nut causes risk of clothing entanglement.
Promptly cut-off flush, file smooth, and treat to prevent corrosion.
Unless Otherwise Specified, All Units of Measure are Each
Note: Peen Tee-Nuts and Flatwashers to match radius of pipe after assembly is complete.
Note: Loctite (supplied by others) should be used on any non-patch hardware.

Issued/Revised:
SHEET 2 OF 7
03/04/13
BT464 INCLINED CLIMBER
Play Systems
1-866-814-8697 bigtoys.com
INSTALLATION INSTRUCTIONS:
1. Dig footing holes as shown in Elevation and Plan Views. Refer to Top View for correct Upright and orientation.
2. Attach Angle Wall to Uprights using 3/8" x 5 3/4" Hex Head Bolt, 3/8" Flat Washer, and 3/8" Lock Nut. See Detail 601.
3. Attach Shroud to Uprights using 1/4" x 1 1/4" P.B.H.C.S and 1/4" Flat Washer (5/8" O.D.). See Detail 603.
4. Attach Angle Wall HDPE to Angle Wall using 3/8" x 3/4" P.B.H.C.S w/Patch, 3/8" Flat Washer, and 3/8” Barrel Nut. See
Detail 602.
5. Attach Handholds to Angle Wall HDPE using 3/8" x 1 1/2" P.B.H.C.S w/Patch, 3/8" Flat Washer, and 3/8” Barrel Nut. See
Detail 604.
6. Attach Cable to Angle Wall using 3/8" x 2 1/2" P.B.H.C.S w/Patch and 3/8" Flat Washer. See Detail 608.
7. Attach Cable to Tabs located on Uprights. See Detail 611.
8. Locate the Playshell and connect Playshell Pipe using Playshell Stop Casting Ass'y. See Detail 001.
9. Attach 15" Cables to Playshell. See Detail 003.
10. Attach 15" Cables to Tabs located on Uprights. See Detail 355.
11. Plumb and level the entire assembly and tighten all fasteners.
12. After entire unit is assembled pour concrete footings within 4” to the top and taper away from post for water drainage. Allow to
cure at least 48 hours before use. Temporary bracing may be required until concrete cures.
13. When the structure is finished and satisfactory, eliminate sharp points and sharp edges (burring) on installed hardware like
bolts, nuts etc. Install resilient surfacing material within the use zone of play structure in accordance with ASTM specifications
F1292 appropriate for the fall height of each structure. Refer to the safety guidelines.
MAINTENANCE PROCEDURE:
Periodically check hardware for tightness, and tighten as necessary. Always check all parts for breakage or wear, and immediately
put equipment out of service until any faulty parts found are repaired or replaced. Also Check all metal parts for rust, paint loss and
touch-up if necessary with paint. Check for welded areas and verify integrity. Check periodically resilient surfacing for appropriate
depth and remove extraneous materials that could cause injury, infection, or disease. Maintain detailed installation, inspection,
maintenance, and repair records for each public-use playground equipment.

Issued/Revised:
SHEET 3 OF 7
03/04/13
BT464 INCLINED CLIMBER
Play Systems
1-866-814-8697 bigtoys.com
FINISHED ASSEMBLY
SHROUD (311350) 601
603
UNDERNEATH
602
604
ANGLE WALL HDPE
(311539)
HANDHOLD
ANGLE WALL
WELD ASS'Y
(311543)
CABLE
(308254)
CABLE
(308254)
611
355
PLAYSHELL (401549)
COMPONENTS SHOWN IN
HIDDEN LINES ARE SOLD SEPARATELY
= INSTALLATION DETAIL
003
608
PLAYSHELL STOP
CASTING ASS'Y
(402250)

Issued/Revised:
SHEET 4 OF 7
03/04/13
BT464 INCLINED CLIMBER
Play Systems
1-866-814-8697 bigtoys.com
56 in
[142.24 cm]
69 1/4 in
[175.92 cm]
90 3/4 in
[230.48 cm]
104 in
[264.16 cm]
33 7/8 in
[86.03 cm]
41 5/16 in
[104.96 cm]
PLAN VIEW
ELEVATION VIEW
RESILIENT
SURFACE
72 15/16 in
[185.29 cm]
45 1/4 in
[114.94 cm]
30 in
[76.20 cm]
10 in
[25.40 cm] BRICK OR EQUIVALENT
CONCRETE REQUIRED
0.436 CUBIC YARDS
[0.332 CUBIC METERS]
n18 in
[45.72 cm]
TYP.
48 in
[121.92 cm]
160 in
[406.40 cm]

Issued/Revised:
SHEET 5 OF 7
03/04/13
BT464 INCLINED CLIMBER
2
1
34
2
5
1
CM
0
INCH0
10961114815
712 13
4
365
1-866-814-8697 bigtoys.com
003
3/4" ID BRONZE
BEARING (817451)
TAB
CABLE
3/4" ID BRONZE
BEARING (817451)
PIN
*LOCTITE (SUPPLIED BY
OTHERS) SHOULD BE USED
ON ANY NON-PATCH
HARDWARE.
001
PLAYSHELL
PLAYSHELL PIPE ASS'Y
(402415)
355
PIN
*LOCTITE (SUPPLIED BY
OTHERS) SHOULD BE
USED ON ANY NON-PATCH
HARDWARE.
3/4" I.D. BRONZE
WASHER (817451)
TAB
CABLE
601
CLIMBER
UPRIGHT
3/8" FLAT WASHER
(817410)
3/8" x 5 3/4" HEX
HEAD BOLT (801051)
3/8" LOCK NUT
(804353)
3/8" FLAT WASHER
(817410)
1/2" x 1/2"
SET SCREW
PLAYSHELL STOP CASTING
(402250)