PlayNation Play Systems Tahoe User manual

Tahoe
ASSEMBLY MANUAL
Copyright © 2009 PlayNation Play Systems, Inc.
All Rights Reserved
Made in the U.S.A.
PlayNation Play Systems, Inc.  190 Etowah Industrial Court  Canton, GA 30114  [phone]
15/MAY/2009 – Version 2.0.0

LAG SCREW
BOARD
SANDBOX
2 X 6 X 70"
3/8 X 3 1/2"
3/8" WASHER
STEP 1: CORNER POSTS
1: PLACE ONE 2 X 6 X 70" SANDBOX BOARD, OFFSET HOLES UP, FLUSH WITH THE BOTTOM OF
TWO 4 X 4 X 96" CORNER POSTS ON THE SIDE WITH ONE THROUGH HOLE. FASTEN THE
SANDBOX BOARD TO THE CORNER POSTS WITH 3/8 X 3 1/2" LAG SCREWS AND 3/8" WASHERS.
2: REPEAT THIS PROCESS FOR THE OPPOSITE SIDE.

STEP 2: BLOCK SUPPORTS
1: INSTALL THE 4 X 4 X 70" BLOCK SUPPORTS TO THE CORNER POSTS AT THE 51-1/2" HOLE.
2: FASTEN THE BLOCK SUPPORTS TO THE CORNER POSTS FROM THE OUTSIDE USING 6-1/2"
CARRIAGE BOLTS WITH TORQUE WASHERS AND 3/8" WASHERS AND 3/8" LOCK NUTS ON THE
INSIDE. MAKE SURE THE COUNTER-SUNK HOLES ARE FACING TO THE INSIDE OF THE UNIT.
3: USE GREEN BOLT CAPS TO COVER ANY EXPOSED THREADS.
6-1/2" CARRIAGE
TORQUE WASHER
BOLT
3/8" WASHER
BLOCK SUPPORT
4 X 4 X70"
3/8" NUT

STEP 3: SANDBOX BOARDS
1: PLACE TWO 2 X 6 X 70" SANDBOX BOARDS, OFFSET HOLES DOWN, FLUSH TO THE BOTTOM
OF THE CORNER POSTS.
2: FASTEN THE SANDBOX BOARDS TO THE CORNER POSTS WITH 3/8 X 3-1/2" LAG SCREWS
AND 3/8" WASHERS.
2 X 6 X 70"
SANDBOX BOARDS
LAG SCREW
3/8 X 3 1/2" 3/8" WASHER

DECK SUPPORT
4 X 4 X 70"
3/8" WASHER
3/8 X 5"
LAG SCREW
STEP 4: DECK SUPPORTS
1: PLACE THE 4 X 4 X 70" DECK SUPPORTS ON TOP OF THE BLOCK SUPPORTS. FASTEN THE DECK
SUPPORTS TO THE CORNER POSTS WITH 3/8 X 5" LAG SCREWS AND 3/8" WASHERS FROM THE
INSIDE.
2: FASTEN THE DECK SUPPORTS TO THE BLOCK SUPPORTS WITH 3/8 X 5" LAG SCREWS AND 3/8"
WASHERS FROM UNDERNEATH

STEP 5: CENTER POSTS
1: PLACE THE 4 X 4 X 84" CENTER POSTS FLUSH WITH THE BOTTOM OF THE BLOCK SUPPORTS,
LINING UP THE PILOT HOLES AT THE CENTER OF THE BLOCK SUPPORTS.
2: FASTEN THE CENTER POSTS TO THE BLOCK SUPPORTS USING 6-1/2" CARRIAGE BOLTS WITH
TORQUE WASHERS, AND 3/8" WASHERS AND 3/8" LOCK NUTS ON THE INSIDE.
3: COVER ANY EXPOSED THREADS WITH BREEN BOLT CAPS.
TORQUE WASHER
4 X 4 X 84"
3/8" NUT
CENTER POST
BOLT
6-1/2"
CARRIAGE
3/8" WASHER

STEP 6: TIRE SWING SUPPORT
1: PLACE THE 4 X 4 X 62-3/4" TIRE SWING SUPPORT FLUSH ON TOP OF THE BLOCK SUPPORTS, IN
LINE WITH THE CENTER POSTS. NO SCREWS ARE NEEDED FOR THE TIRE SWING SUPPORT.
2: PLACE THE 2 X 4 X 70" CENTER DECK SUPPORTS FLUSH AGAINST THE CENTER POSTS, ON TOP
OF THE BLOCK SUPPORTS. MAKE SURE THE OFFSET HOLES ON ONE CENTER DECK SUPPORT ARE
UP AND THE HOLES ON THE OTHER SIDE ARE DOWN. FASTEN THE CENTER DECK SUPPORTS TO
THE CENTER POSTS AND THE TIRE SWING BEAM WITH 3-1/2" LAG SCREWS AND 3/8" WASHERS.
4 X 4 X 62-3/4"
TIRE SWING SUPPORT
3/8" WASHER
SUPPORT
CENTER DECK
2 X 4 X 70"
3/8 X 3-1/2"
LAG SCREW

4 X 4 X 25"
WASHER
TIRE SWIVEL
CARRIAGE BOLT
3/8" WASHER
LAG SCREW
BLOCK
4-1/2"
3/8" NUT AND
TORQUE
3/8 X 5"
3/8" WASHER
STEP 7: BLOCKS AND TIRE SWIVEL
1: PLACE THE 4 X 4 X 25" BLOCKS FLUSH ON TOP OF THE BLOCK SUPPORTS, BETWEEN THE
CENTER AND END DECK SUPPORTS. FASTEN THE BLOCKS TO THE BLOCK SUPPORTS WITH 3/8 X 5"
LAG SCREWS AND 3/8" WASHERS.
2: PLACE THE TIRE SWIVEL ON TOP OF THE TIRE SWING SUPPORT, ON CENTER. MARK THE BOLT
HOLES OF THE TIRE SWIVEL, THEN PROCEED TO DRILL TWO 3/8" PILOT HOLES THROUGH THE TIRE
SWING SUPPORT. MOUNT THE TIRE SWIVEL TO THE TIRE SWING SUPPORT USING 4-1/2" CARRIAGE
BOLTS WITH TORQUE WASHERS FROM THE TOP AND 3/8" WASHERS AND 3/8" LOCK NUTS ON THE
BOTTOM.

STEP 8: DECK PANELS
1: PLACE ONE 3-BOARD DECK ON TOP OF THE DECK SUPPORTS, IN FRONT OF EACH OF THE
CENTER POSTS, ALLOWING THE 2 X 4 DECK STREAMERS TO OVERLAP THE DECK SUPPORTS.
2: TO THE SIDE OF THE 3-BOARD DECKS, PLACE A 2-BOARD DECK AND SECURE THE DECKS TO
THE DECK SUPPORTS WITH 2" WOOD SCREWS.
DECK PANEL
DECK SUPPORT

POST
3/8" NUT
TORQUE WASHER
6-1/2" CARRIAGE
BOLT
4 X 6 X 38"
END CENTER
3/8" WASHER
STEP 9: END CENTER POSTS
1: PLACE THE 4 X 6 X 38" END CENTER POST AGAINST THE DECK SUPPORTS AND LINE UP THE PILOT
HOLES.
2: FROM THE INSIDE, FASTEN THE END CENTER POSTS TO THE DECK SUPPORTS USING 6-1/2"
CARRIAGE BOLTS WITH TORQUE WASHERS FROM THE OUTSIDE, AND 3/8" NUTS AND WASHERS
FROM THE INSIDE.
3: USE GREEN BOLT CAPS TO COVER ANY EXPOSED THREADS.

5/4 X 6 X 63"
CENTER DECK BOARD
STEP 10: CENTER DECK BOARD
1: PLACE THE 5/4 X 6 X 63" CENTER DECK BOARD ACROSS THE TOP OF THE DECK SUPPORTS,
BETWEEN THE 2-BOARD DECKS.
2: SECURE THE CENTER DECK BOARD TO THE DECK SUPPORTS WITH 2" WOOD SCREWS.

3/8" WASHER
BOLT
4 X 4 X 118"
5" LAG
3/8" NUT
SCREW
SIDE RAIL
6-1/2" CARRIAGE
TORQUE WASHER
4 X 4 X 118"
SWING BEAM
SIDE RAIL
STEP 11: SIDE RAILS
1: INSTALL THE 4 X 4 X 118" SIDE RAILS TO THE CORNER POSTS AT THE 86" HOLE. FASTEN THE
SIDE RAILS FROM THE INSIDE USING 6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS, AND 3/8"
NUTS AND 3/8" WASHERS ON THE OUTSIDE.
2: THE SWING BEAM SIDE RAIL WILL INSTALL IN THE SAME MANNER AS THE SIDE RAIL. ONE
IMPORTANT NOTE IS THAT THE SIDE WITH FIVE COUNTER-SUNK HOLES MUST FACE DOWN.
3: FASTEN THE SIDE RAILS TO THE CENTER POSTS WITH 5" LAG SCREWS AND 3/8" WASHERS.
4: USE GREEN BOLT CAPS TO COVER ANY EXPOSED THREADS.

STEP 12: TRAPEZE ARMS
1: PLACE THE 4 X 6 X 115" TRAPEZE ARM ON TOP OF THE SIDE RAILS FLUSH TO THE REAR
CORNER POSTS. WITH A 3/8" DRILL BIT, DRILL A HOLE THROUGH THE 4 X 6 X 115" TRAPEZE ARMS
AND THE CORRESPONDING CORNER POSTS.
2: FASTEN THE TRAPEZE ARM TO THE REAR CORNER POSTS FROM THE INSIDE USING 6-1/2"
CARRIAGE BOLTS WITH TORQUE WASHERS AND 3/8" NUTS WITH 3/8" WASHERS ON THE OUTSIDE.
3: PLACE THE 4 X 6 X 115" ROPE LADDER SUPPORT ON TOP OF THE SIDE RAILS FLUSH TO THE
FRONT CORNER POSTS. WITH A 3/8" DRILL BIT, DRILL A HOLE THROUGH THE 4 X 6 X 115" TRAPEZE
ARMS AND THE CORRESPONDING CORNER POSTS.
4: FASTEN THE ROPE LADDER SUPPORT TO THE FRONT CORNER POSTS FROM THE INSIDE USING
6-1/2" CARRIAGE BOLTS WITH TORQUE WASHERS AND 3/8" NUTS WITH 3/8" WASHERS ON THE
OUTSIDE.
5: FROM UNDERNEATH THE SIDE RAILS, LOCATE THE COUNTER-SUNK HOLES THAT LINE UP WITH
THE 4 X 6 X 115" TRAPEZE ARMS. SECURE THE SIDE RAILS TO THE TRAPEZE ARM WITH 5" LAG
SCREWS AND 3/8" WASHERS.
6: FASTEN THE CENTER END POSTS TO THE TRAPEZE ARM WITH 5" LAG SCREWS AND 3/8"
WASHERS.
7: USE GREEN BOLT CAPS TO COVER ANY EXPOSED THREADS.
TRAPEZE ARM
4 X 6 X 115"
WASHER
3/8" WASHER
BOLT WITH 1/2"
5" LAG SCREW
3/8" WASHER
SCREW
5" LAG
AND WASHER
3/8" NUT
6-12" CARRIAGE
4 X 6 X 115"
ROPE LADDER SUPPORT

FROM THE INSIDE OF THE LADDER RAILS.
LADDER TO THE END CENTER AND CORNER POSTS USING 5" LAG SCREWS AND 3/8" WASHERS
LADDER
SCREW
3/8" WASHER
5" LAG
ATTACH THE PRE-ASSEMBLED LADDER TO THE END CENTER AND CORNER POSTS. FASTEN THE
STEP 13: LADDER

SIDE PANEL
SIDE PANEL
5" LAG
SCREW
BACK PANEL
3/8"
WASHER
STEP 14: PANELS
1: PLACE THE FOUR PRE-ASSEMBLED SIDE PANELS ON TOP OF THE DECK SUPPORT AND CENTER
DECK SUPPORT. SEE BELOW FOR DETAILS. ATTACH BOTTOM OF PANEL TO DECK SUPPORTS WITH
2-1/2" WOOD SCREWS.
2: FASTEN TOP OF SIDE PANELS TO THE SIDE TARP SUPPORTS WITH 5" LAG SCREWS AND 3/8"
WASHERS.
3: PLACE THE TWO PRE-ASSEMBLED BACK PANELS ON TOP OF THE DECK BOARDS. ATTACH
BOTTOM OF PANEL TO DECK BOARDS WITH 2-1/2" WOOD SCREWS.
4: FASTEN TOP OF BACK PANELS TO THE TRAPEZE ARM WITH 5" LAG SCREWS AND 3/8" WASHERS.

STEP 15: ROOF SUPPORTS
3/8" WASHER
3-1/2" LAG
IF THIS IS NOT DONE, THE ROOF BOARDS WILL NOT INSTALL PROPERLY.
5" LAG
SCREW
2: ADJUST THE ROOF SUPPORTS SO THAT THE SIDES ARE FLUSH WITH THE ENDS OF THE SIDE RAILS.
3: ONCE THE ROOF SUPPORTS ARE ADJUSTED, ATTACH THEM TO THE SIDE RAILS WITH 5" LAG
SCREWS AND 3/8" WASHERS.
SCREW
3/8" WASHER
1: ATTACH THE 4 X 4 X 76" ROOF SUPPORTS AT THE TOP OF THE CENTER POSTS WITH 3-1/2" LAG
SCREWS AND 3/8" WASHERS. THE ANGLED ENDS OF THE ROOF SUPPORTS WILL BE FLUSH TO THE
TOP OF THE CENTER POSTS.
4 X 4 X 76"
ROOF SUPPORT

STEP 16: SLIDE
PLACE THE SLIDE ON TOP OF THE DECK, OVERLAPPING THE DECK BOARDS. ATTACH THROUGH
THE DECK WITH 1-1/4" WOOD SCREWS.

SCREW
2 X 6 X 70" FILLER BOARD
3-1/2" LAG
3/8" WASHER
STEP 17: FILLER BOARD
PLACE THE 2 X 6 X 70" FILLER BOARD WITH OFFSET HOLES DOWN FLUSH TO THE TOP OF THE
DECK BOARDS. ATTACH TO THE CORNER POSTS WITH 3-1/2" LAG SCREWS AND 3/8" WASHERS.

TORQUE WASHER
3/8" WASHER
BOLT
6-1/2" CARRIAGE
3/8" NUT
SPRING CLIP
SWING CHAIN
STEP 18: SWINGS
1: FASTEN THE SWING DUCTILE TO THE BOTTOM OF THE TRAPEZE ARM USING 6-1/2" CARRIAGE
BOLTS WITH TORQUE WASHERS ON TOP OF THE BEAM, AND 3/8" WASHERS AND NUTS ON THE
BOTTOM.
2: HANG THE SWINGS FROM THE IRON DUCTILES USING THE SPRING CLIPS. HANG THE TIRE
SWING FROM THE TIRE SWIVEL USING THE SPRING CLIP. ADJUST CHAINS FOR HEIGHT IF
NECESSARY.
3: USE GREEN BOLT CAPS TO COVER ANY EXPOSED THREADS.
SPRING CLIP
SWING CHAIN
TIRE SWIVEL

3/8" WASHER
4 X 4 X 16"
SCREW
5" LAG
SCREW
FORT SUPPORT
3-1/2" LAG
3/8" WASHER
STEP 19: FORT SUPPORTS
1: PLACE THE 4 X 4 X 16" FORT SUPPORTS WITH COUNTER-SUNK HOLES FACING OUT ON THE
CORNER POSTS. THE 45 END SHOULD BE AGAINST THE CORNER POST, AND THE OTHER
SHOULD BE LEVEL TO THE TOP OF THE BLOCK SUPPORTS. SEE BELOW FOR CLARIFICATION.
2: FASTEN THE FORT SUPPORTS TO THE BLOCK SUPPORTS WITH 5" LAG SCREWS AND 3/8"
WASHERS, AND TO THE CORNER POSTS WITH 3-1/2" LAG SCREWS AND 3/8" WASHERS.