Rainbow Play Systems Carnival Castle User manual

COPYRIGHT 2012 RAINBOW PLAY SYSTEMS, INC. ALL RIGHTS RESERVED
RAINBOW RESERVES THE RIGHT TO MAKE CHANGES AND MODIFICATIONS TO THIS PRODUCT.
!
WARNING: This owner's manual contains important information about how to assemble, locate, use,
and maintain this playground equipment. Read this manual before you start assembly. Follow all
instructions. Be sure to educate all children who use this playground and all adult supervisors about
the rules for safe use that are contained in this manual.
Keep this Owner's Manual for future reference and to remind you of how to safely use and maintain this equipment.
Carnival Castle
Assembly Instructions
5-70-0301
(Rev 0 - 12.14.11)
Contains Assembly, Use, and Maintenance Instructions
NOTICE: This product is intended for outdoor family domestic use only with
children ages 3 to 12. This product is not suitable for children under 36 months.

OWNER'S MANUAL
Rainbow Play Systems, Inc.
Thank you for choosing Rainbow Play Systems, Inc. Please read the
instruction manual thoroughly before you start building your Carnival
Castle to help ensure safe installation. Familiarize yourself with all
hardware and parts to help with building your playground.
WARNING: Failure to follow the assembly, location, use, and
maintenance instructions in this manual could result
in serious injury to children using this playground.
Rules for Safe Play..........................................................................2
Choosing Location of Play System..................................................3
Choosing Proper Surface Material...................................................3-4
Maintenance....................................................................................4
Helpful Tips.....................................................................................5
Commonly Asked Questions...........................................................6
Parts Identification...................................................................7-12, 17-18
Hardware.........................................................................................12-16
Tools Required for Assembly..........................................................16
Instructions......................................................................................19-57
Warranty..........................................................................................58
1

Thoroughly read all Safety Instructions on pages 2-5 before beginning assembly of
your playset.
Welcome to RAINBOW
Welcome to our family of ready-to-build residential play equipment. Ease of assembly has been pre-engineered into
our product and we provide step-by-step installation instructions.
To ensure safe play for your children, before building your play system, please take some time with your children and
go over the Rules for safe play on your play system. Do not allow children in the area while you are assembling
your play system. Many of Rainbow's components are very heavy and could seriously injure a child. Observing these
rules reduces the likelihood of serious or fatal injury.
After thoroughly reading the information below, locate your play site and carefully unpack parts. As you
unpack your play system, keep the parts list handy and become familiar with each part before beginning assembly.
Remember that a little extra time spent familiarizing yourself with the parts and the instructions before you begin will
help to avoid mistakes and save you time later. Please keep these instructions for future reference.
This product is recommended for children 3 to 12 years of age.
Note: This product is not intended for public use. Rainbow Play Systems, Inc. does not
warranty its Residential Play Equipment subject to commercial use.
Safety Instructions
Rules for Safe Play
WARNING: Before allowing children to play on this equipment for the first time, carefully review
the rules for safe play with them. Observing the following statements and warnings
reduces the likelihood of a serious or fatal injury.
1.
IT IS RECOMMENDED that no more than 6-8 children, not exceeding a combined weight of 1,200 pounds, play on the
system at one time. This product is recommended for children 3 to 12 years of age.
2. CLOSE ADULT SUPERVISION is required for children of all ages.
3. WARN CHILDREN TO AVOID playing or walking in front of, behind, or between moving equipment.
4. WARN CHILDREN NOT TO twist swing chains or ropes, or to loop them over the top support bar since this may reduce the
strength of the chain or rope.
5. INSTRUCT CHILDREN NOT TO swing empty seats, trapeze bar, gliders, buoy balls or tire swings.
6. INSTRUCT CHILDREN to always sit, never stand or kneel, in the center of the swing seat with their full weight.
7. INSTRUCT CHILDREN NOT TO use any part of the play system in a manner other than what it is intended.
8. INSTRUCT CHILDREN NOT TO get off equipment while it is in motion.
9. DRESS CHILDREN APPROPRIATELY. CHILDREN SHOULD NOT wear scarves, hats with straps, helmets, jackets with
draw strings, hooded jackets, poorly fitting shoes, or any other loose fitting clothing that is potentially hazardous while
using equipment.
10. INSTRUCT CHILDREN NOT TO play on the equipment if it is wet. Potentially slippery surfaces may cause a hazard.
11. VERIFY all suspended items such as ropes and chains are secure at both ends.
12. VERIFY all suspended items such as climbing ropes are tight so they cannot be looped back on themselves.
13. INSTRUCT CHILDREN NOT TO attach items to the play system not specifically intended for use with the play equipment.
Items such as, but not limited to, jump ropes, clotheslines, pet leashes, cables and chain may pose a strangulation hazard.
14. INSTRUCT CHILDREN TO REMOVE any bike or other sports helmets before playing on the play equipment, as they may
pose a possible hanging hazard. Children must be dressed appropriately.
15. INSTRUCT CHILDREN there may only be one person on a swing at a time with a maximum weight of 150 pounds per swing.
16. VERIFY there are no gaps between the slide bed way and the slide screws.
17. INSTRUCT CHILDREN to always go down slides feet first. Never slide head first.
18. INSTRUCT CHILDREN TO NEVER climb, crawl, or walk on items not intended for such use. Such types of play on top of
Monkey Bars, Fort Roof, and Swing Beams greatly increase the risk of a serious or fatal fall.
2

min.
6'
Beam Height
2x Swing
Beam Height
2x Swing
min.
6'
6' min.
6' min.
6' min.
6' min.
6' min.
6' min.
2x Swing
Beam Height
2x Swing
Beam Height
Choosing a location for your play system
When selecting your play site, always keep the child's safety in mind. Here are some recommendations that should help you achieve a safe
play area.
1. The play system should be located on solid level ground free of objects that could cause injury such as, but not limited to, tree stumps,
roots, and large rocks. Stationary components such as ladders and slides must be no less than SIX FEET (1.8 meters) from any
structure or obstruction such as a fence, garage, house, tree or overhanging branches, electrical wires or clotheslines. Any swinging
equipment must be a minimum distance of TWICE the height of the swing beam away from any structures or obstructions as specified
above. We also recommend that you do not install your play system near a lake, river, swimming pool or other water hazards.
2. If anchoring your play system, all underground utilities must be located in play zone before starting assembly of play system.
3. Try to locate slide out of direct sunlight to reduce the likelihood of serious burns. A slide that faces north will receive the least direct
sunlight.
4. It is recommended not to place a set on sandy soil or loose fill as it may require additional anchoring in that situation.
5. Do not install your play system over concrete, asphalt, packed earth, grass, carpet, or any other hard surface. A fall onto a hard surface
can result in serious injury to the play system user.
Choosing a surfacing material
The consumer shall provide playground surfacing materials under and around residential play equipment that conforms to the
recommendations of the Consumer Product Safety Commission's Outdoor Home Playground Safety Handbook publications #324. A copy
of the section relating to surfacing materials is included in the installation instructions. Free copies of this handbook are available on line at
www.cpsc.gov or by contacting the CPSC Publications Office in Washington D.C. 20207.
Playground equipment should never be placed on hard surfaces such as concrete or asphalt. Do not use loose fill surfacing on top of hard
surfaces such as concrete or asphalt. While grass may appear to be acceptable, it may quickly turn to hard packed earth in areas of high
traffic. Shredded bark mulch, wood chips, fine sand or fine gravel are considered to be acceptable shock absorbing surfaces when installed
and maintained at a sufficient depth under and around playground equipment. The U.S. Product Safety Commission (CPSC) estimates that
about 100,000 playground equipment-related injuries resulting from falls to the ground surface are treated annually in U.S. hospital's
emergency rooms. Injuries involving this hazard pattern tend to be the most serious of all playground injuries, and have a potential to be
fatal, particularly when the injury is to the head. The surface under and around playground equipment can be a major factor in determining
the injury-causing potential of a fall. It is self evident that a fall onto a shock absorbing surface is less likely to cause a serious injury than a
fall onto a hard surface.
The following information is intended to assist in comparing the relative shock-absorbing properties of various materials. No particular
material is recommended over another. However, each material is only effective when properly maintained. Materials should be checked
periodically and replenished to maintain correct depth as determined necessary for your equipment. The choice of a material depends on
the type and height of your playground equipment, the availability of the material in your area, and its cost.
Table 3.1 lists the maximum height from which a child would not be expected to sustain a life-threatening head injury in a fall onto four
different loose-fill surfacing materials if they are installed and maintained at depths of 6, 9, and 12 inches. However, it should be recognized
that all injuries due to falls cannot be prevented no matter what surfacing material is used.
The URL is http://www.cpsc.gov/cpscpub/pubs/324.pdf and the file size is 456.5KB
For Specific or other configurations refer to the webite for set dimensions and play areas.
Set Dimensions Play Zone
L 20 1/2' x W 11 1/2' x
H 12'
L 32 1/2' x W 29'
3

NOTICE: It is recommended to use containment, such as digging out around the perimeter and/or lining the perimeter with
landscape edging for surfacing materials.
Installations of rubber tiles or poured-in-place surfaces (other than loose-fill materials) generally require a professional and are
not "do-it-yourself" projects.
When surfacing is to be used it is recommended to use Playground Surfacing Materials (other than loose-fill materials) which
comply to the safety standard ASTM 1292 Standard Specification for Impact Attenuation of Surfacing Materials within the Use
Zone of Playground Equipment.
Maintenance of your play system
To ensure safe enjoyment of your Rainbow Play System for years to come, follow these maintenance tips:
1. At the beginning of each usage season and twice each month, check and tighten as needed (but do not over
tighten causing the wood to crack) all nuts and bolts. Acorn nuts should be tightened to 5 foot pounds of torque.
Hardware used on swinging elements should be checked at least twice a month to ensure proper fastening.
2. At the beginning of each usage season and twice each month, check all coverings for bolts and sharp edges
to be certain they are in place. Replace when necessary.
3. Oil all metallic moving parts and grease Tire Swivel monthly during the usage period.
4. Check all moving parts including swing seats, ropes, and chains for wear, rust, or other deterioration and replace
as needed.
5. Check all metal parts for rust. If needed, sand and repaint using a nonlead-based paint meeting the
requirements of Title 16 CFR Part 1303.
6. Check the S-Hooks on the chains to ensure the gap is less than .040 inches. Tighten/close as necessary.
7. Remove plastic swing seats and take indoors or do not use when temperature drops below 32 Fahrenheit.
Reinstall swing seats when the cold season is complete.
8. Check, twice a month, the depth of loose fill protective surfacing materials to prevent compaction and to
maintain appropriate depth. Rake or replace as necessary.
9. When you are ready to dispose of your playset, make sure all metal, plastic and wood components are
disposed of in accordance with local waste ordinances and ensure that no unreasonable hazards exist.
10. On a yearly basis, we recommend that you coat your play system with a sealant or preservative. You may
also want to spot sand areas before sealing. Be sure that the sealant you select is non-toxic and child safe.
11. Check all wood members for deterioration and splinters. Spot sand any areas that are checking or
splintering. If parts are deteriorating, replace as needed.
Chart obtained from U.S. Consumer Product Safety Commission Handbook for Public Playground Safety
Surfacing in "compressed" depths - See CPS & ASTM for Fall Heights of equipment
Equipment Fall Height 1' 2' 3' 4' 5' 6' 7' 8' 9' 10' 11' 12'
Wood Chips 6" 6" 6" 6" 6" 6" 6 1/2" 7 1/2" 8 1/4" 9" 12" 13"
Double Shredded Bark Mulch 6" 6" 6" 6" 7" 8" 9" 9 3/4" 10 1/2" 11 1/2" 12" 13"
Engineered Wood Fibers 6" 6" 6" 7" 8 1/2" 9" 9 1/2" 10 1/4" 10 3/4" 11" 10 3/4" 12"
Fine Sand 6" 6" 6 1/2" 8" 9 10" 10 1/2" 11 1/4" 12" 13 1/2" 14 3/4" 16"
Coarse Sand 6" 6" 7 1/2" 9" 10 1/2" 12" 14" 16" 18" 20" 22" 24"
Fine Gravel 6" 6" 6" 6 3/4" 8" 9" 10" 10 3/4" 11 1/2" 12" 13 1/4" 14 1/2"
Medium Gravel 6" 6 1/4" 8" 9" 9" 12" 14" 16" 18" 20" 22" 24"
TABLE 3.1 Fall Height in Feet From Which a Life Threatening Head Injury Would Not Be Expected
Type of Material 6 in. depth 9 in. depth 12 in. depth
Double Shredded Bark Mulch 6 ft. 10 ft. 11 ft.
Wood Chips 6 ft. 7 ft. 12 ft.
Fine Sand 5 ft. 5 ft. 9 ft.
Fine Gravel 6 ft. 7 ft. 10 ft.
4

DETAIL A
UPRIGHT
PILOT
HOLES
FACIA
DETAIL B
USE FACIA AS
A GUIDE FOR
PRE-DRILLING
HOLES
FACES MUST
BE FLUSH
Helpful Installation Hints
1. Wear safety glasses to protect your eyes from flying wood chips when drilling or cutting.
2. Verify that all bolts and screws are secured tightly and all acorn nuts are snug (acorn nuts should be
tightened to 5 foot pounds of torque).
3. DO NOT allow children to play on the play system until it is completely assembled in a proper location.
4. DO NOT allow children in the area while you are assembling your play system. Many of the Rainbow Play
Systems, Inc. components are very heavy and could seriously injure a child.
5. After thoroughly reading all information and properly locating your play system site, carefully unpack
parts. As you unpack your play system, keep the parts list handy and become familiar with each part before
beginning assembly. Remember that a little extra time spent familiarizing yourself with the parts and
instructions before you begin will help avoid mistakes and save you time later.
6. Group both wood and non-wood parts together in accordance to each page, or Step, of this assembly
manual. Doing this now will help you quickly locate parts and assemble the set with ease.
7. Sort your hardware into groups of similar hardware pieces. Use a solid surface, such as the empty boxes, to
ensure you do not lose any hardware.
8. Before starting each Step, thoroughly read all of the instructions to ensure all information is understood. Pay
special attention to the orientation of each part, details & notes, and proper usage of hardware. Each piece of
hardware is required for a certain part of the assembly.
9. Certain steps of the assembly are best performed on a hard flat surface to ensure proper and accurate
assembly.
10. All Lag Bolts must have pre-drilled holes 2" deep (as shown in Detail A). Use a 1/8" drill bit for all 1/4" and
5/16" Lag Bolts and use a 1/4" drill bit for all 3/8" Lag Bolts. Lag Bolts can be difficult to put in knot holes.
Pre-drilling pilot holes will help to prevent the Lag Bolts from breaking.
11. All #14 Phillips Pan Head Tap Screws must have pre-drilled holes 1/2" deep. Use a 1/8" drill bit.
12. Use a clamp to secure facias flush to the Uprights and use holes in facia as a guide for placing Lag Bolt Pilot
Holes (as shown in Detail B).
13. Verify Facias are flush with Uprights.
14. Check assembly periodically to ensure the set is level and all facias are square to the uprights.
15. If a gap occurs between boards when inserting Screws or Lag Bolts, back out hardware and apply pressure to
the top board while reinserting hardware in the same hole.
WARNING
Drilling, sawing, sanding or machining wood products generates wood dust,
a substance known to the State of California to cause cancer. Avoid inhaling
wood dust or use a dust mask or other safeguards for personal protection.
California Health and Safety Code Section 25249.6
5

EXAMPLE OF SEASONAL
CHECKS OR SURFACE
CRACKS
COMMONLY ASKED QUESTIONS
Question: How do I know when Lag Bolts and other Fasteners are tightened properly?
Answer: Lag Bolts and other Fasteners are tight when the head of the Lag Bolt and Washer
are firmly compressed against the wood. If splintering occurs, that is an indication you
are over tightening the Lag Bolts and other Fasteners. (Splintering is when the wood
fibers fracture out from under the washers).
Question: What should I do if a Lag Bolt or other Fastener lines up with a knot, or if the Lag Bolt
breaks?
Answer: There is extra Hardware provided with the set for this reason. Re-Drill a new hole with
a 1/8" Drill Bit in a new direction to miss the obstruction.
Question: What if my Play System is leaning and/or rocks?
Answer: This is caused by unleveled ground under the Base and Support Wings of the Play
System. It may be necessary to remove or add some soil beneath the Play System
to make it level. Ground Stakes, when installed, will also provide stability.
Question: What if my Play System has cracks on the wood or seems to be developing cracks?
Answer: Seasonal checks, surface cracks, and knot holes are natural characteristics of all
wooden play equipment. A check is a separation of the wood fibers running with the
grain. This is caused by varying temperature and moisture conditions. By coating
your Play System annually with a sealant or preservative, you can help protect your
Play System from developing (not stopping) seasonal checks. Please remember to
follow all installation instructions, including installing the play set on solid level ground.
Question: What is the sticky substance that appears on the wood?
Answer: The sticky substance that may appear on the wood is called pitch. It is common for
the lumber to have occasional pitch seepage which does not affect the structural
integrity of the part. Pitch provides the natural rot resistant characteristics of the
lumber. If play surfaces or play items become overly sticky with pitch use rubbing
alcohol to safely remove.
Question: What accessories may be added or what modifications can be made to my Rainbow
boxed kit set?
Answer: Rainbow boxed kit sets are complete kits and are not modular. Play sets with
unauthorized accessories or modifications will not be covered under warranty.
Non-residential use of the play set voids warranty.
Question: Is my child old enough to use all play items on my set?
Answer: All play items on Rainbow boxed kit sets are designed
for children ages 3 to 12, but it is the end users
responsibility to determine suitability of use by their
children for each play item.
6

200 255
257 258
256
263
264
265
385
267
266
77
78
81 82
268
269 270
272271
273
274
275
6 @ 1 x 4 x 27 1/2" RAIL UPRIGHT
(3-01-0037)
2 @ 1 x 6 x 27 1/2" RAIL UPRIGHT (3-02-0009)
1 @ 1 x 6 x 6" RAIL UPRIGHT
(3-02-0018)
1 @ 1 x 6 x 11 1/2" RAIL
UPRIGHT (3-02-0011)
2 @ 1 x 6 x 27 1/2" BUBBLE RAIL
UPRIGHT (3-02-0010)
2 @ 2 x 4 x 74" CENTER UPRIGHT (3-03-0031)
2 @ 2 x 4 x 51" 2 HOLE FACIA (3-03-0032) 1 @ 2 x 4 x 17" TIC TAC TOE BOARD (3-03-0037)
1 @ 2 x 6 x 17" TIC TAC TOE BOARD (3-04-0010) 1 @ 2 x 4 x 45" TARP BOARD (3-03-0040)
2 @ 2 x 6 x 79 11/16" MAIN BEAM (3-04-0009)
2 @ 4 x 4 x 104" A-FRAME LEG (3-06-0003)
1 @ 4 x 4 x 60" A-FRAME CROSS MEMBER (3-06-0004)
1 @ 4 x 4 x 15" UPPER A-FRAME BRACKET
(3-06-0007)
1 @ 4 x 4 x 15" LOWER A-FRAME BRACKET
(3-06-0008)
1 @ 4 x 4 x 82" CASTLE STEP LADDER LEG (3-06-0012)
4 @ 4 x 4 x 14" ANGLED BRACE
(3-06-0013)
1 @ 4 x 4 x 65" GROUND RUNNER (3-06-0014)
1 @ 4 x 4 x 51" CASTLE FRONT BEAM (3-06-0015) 4 @ 4 x 4 x 38" CORNER UPRIGHT
(3-06-0016)
2 @ 4 x 4 x 82" ROCK WALL LEG (3-06-0017)
1 @ 4 x 4 x 88 7/8" LOWER ROPE RUNNER (3-06-0018)
1 @ 4 x 4 x 81 1/2" UPPER ROPE ARM (3-06-0019)
CIRCUS CASTLE PARTS LIST
7

276
277
278
279
384
346
283
285
287 288
286
284
289
290 291
293292
294 354
303
305304
302
1 @ 4 x 4 x 64" MIDDLE STEP/RUNG COMBO LEG (3-06-0020)
1 @ 4 x 4 x 82" CASTLE RUNG LADDER LEG (3-06-0021)
1 @ 4 x 4 x 93" TOP JOIST w/MB HOLES (3-06-0022)
1 @ 4 x 4 x 93" TOP JOIST w/SWING HOLES (3-06-0023)
1 @ 4 x 4 x 6" PIPE BLOCK (3-06-0029)
1 @ 4 x 6 x 106" 3 POSITION SWING BEAM (3-07-0006)
2 @ 5/4 x 4 x 45" ROCK WALL BOARD
(3-09-0011)
8 @ 5/4 x 4 x 45" 2 HOLE ROCK WALL BOARD
(3-09-0012)
1 @ 5/4 x 4 x 45" ROCK WALL BOARD w/ROPE HOLE
(3-09-0014)
9 @ 5/4 x 4 x 44 7/8" DECK BOARD (3-09-0016)
8 @ 5/4 x 4 x 45" 2 HOLE INSIDE ROCK WALL
BOARD (3-09-0013)
4 @ 5/4 x 4 x 39" SHORT DECK BOARD
(3-09-0015)
1 @ 5/4 x 4 x 72" DECK RUNNER (3-09-0017)
1 @ 5/4 x 4 x 13" TIRE SWING BOARD
(3-09-0018)
1 @ 5/4 x 4 x 56 3/4" 2 HOLE FACIA (3-09-0019)
6 @ 5/4 x 4 x 26" ROPE RUNG (3-09-0021) 1 @ 5/4 x 4 x 30" FRONT FACIA (3-09-0020)
1 @ 5/4 x 4 x 60 1/2" ROCK WALL RUNNER (3-09-0022)
2 @ 5/4 x 6 x 79 11/16" ANGLED FACIA (3-10-0005)
4 @ 5/4 x 4 x 16 1/4" WINDOW FRAME
(3-09-0032)
4 @ 5/4 x 6 x 20" LADDER
STEP (3-10-0006)
2 @ 5/4 x 6 x 39" SHORT DECK BOARD (3-10-0007) 4 @ 5/4 x 6 x 44 7/8" DECK BOARD (3-10-0008)
CIRCUS CASTLE PARTS LIST
8

200 245
247246
248
250
249
251
252
329
253
362
364
366
368
363
365
367
370369
371 372
374
376
373
375
377 259
260
2 @ 1 x 4 x 27 1/2" RAIL UPRIGHT
(3-01-0037)
42 @ 1 x 4 x 45 1/4" ROOF BOARD (3-01-0050)
2 @ 1 x 4 x 17" FAN VERTICAL (3-01-0052)
4 @ 1 x 4 x 10 3/4" CABIN HORIZONTAL
(3-01-0054)
4 @ 1 x 4 x 17 7/8" CABIN HORIZONTAL
(3-01-0056)
2 @ 1 x 4 x 13" WINDOW HORIZONTAL
(3-01-0070)
2 @ 1 x 4 x 8 3/4" FAN RAY (3-01-0098)
1 @ 1 x 4 x 15 5/8" LEFT DORMER BOARD
(3-01-0100)
4 @ 1 x 4 x 11 1/2" FAN RAY (3-01-0051)
4 @ 1 x 4 x 11 3/8" CABIN HORIZONTAL
(3-01-0053)
4 @ 1 x 4 x 14 5/8" CABIN HORIZONTAL
(3-01-0055)
4 @ 1 x 4 x 21 1/8" CABIN HORIZONTAL
(3-01-0069)
4 @ 1 x 4 x 6 1/2" CHIMNEY TRIM
(3-01-0092)
1 @ 1 x 4 x 13" FAN VERTICAL (3-01-0099)
1 @ 1 x 4 x 13 9/16" LEFT DORMER BOARD
(3-01-0101)
1 @ 1 x 4 x 9 1/2" LEFT DORMER BOARD
(3-01-0103)
1 @ 1 x 4 x 5 7/16" LEFT DORMER BOARD
(3-01-0105)
1 @ 1 x 4 x 11 9/16" LEFT DORMER BOARD
(3-01-0102)
1 @ 1 x 4 x 7 1/2" LEFT DORMER BOARD
(3-01-0104)
1 @ 1 x 4 x 3 3/8" LEFT DORMER BOARD
(3-01-0106)
1 @ 1 x 4 x 15 5/8" RIGHT DORMER BOARD
(3-01-0107)
1 @ 1 x 4 x 13 9/16" RIGHT DORMER BOARD
(3-01-0108)
1 @ 1 x 4 x 9 1/2" RIGHT DORMER BOARD
(3-01-0110)
1 @ 1 x 4 x 5 7/16" RIGHT DORMER BOARD
(3-01-0112)
2 @ 1 x 6 x 43 1/2" FAN HORIZONTAL (3-02-0019)
1 @ 1 x 6 x 86" NOTCHED CABIN HORIZONTAL (3-02-0020)
1 @ 1 x 4 x 11 9/16" RIGHT DORMER BOARD
(3-01-0109)
1 @ 1 x 4 x 7 1/2" RIGHT DORMER BOARD
(3-01-0111)
1 @ 1 x 4 x 3 3/8" RIGHT DORMER
BOARD (3-01-0113)
WOOD ROOF ADD-ON PARTS LIST
9

261 262
379378
360
361
356
383
355
357
297
298 299
301300
380 381
306
307
308 382
2 @ 1 x 6 x 26 1/8" NOTCHED CABIN
HORIZONTAL (3-02-0021)
2 @ 1 x 6 x 53" CABIN HORIZONTAL (3-02-0022)
1 @ 1 x 6 x 12 1/8" CHIMNEY BACK (3-02-0026) 1 @ 1 x 6 x 18" CHIMNEY FRONT
(3-02-0025)
2 @ 2 x 4 x 69 1/2" RIGHT ROOF SUPPORT (3-03-0048)
2 @ 2 x 4 x 69 1/2" LEFT ROOF SUPPORT (3-03-0049)
1 @ 2 x 4 x 26" FAN HORIZONTAL
(3-03-0050)
1 @ 2 x 4 x 6" FAN CENTER (3-03-0051)
2 @ 2 x 6 x 8" FAN CENTER (3-04-0005)
1 @ 2 x 4 x 24 1/4" LEFT DORMER
SUPPORT (3-03-0052)
2 @ 5/4 x 4 x 66 1/2" ROOF RUNNER (3-09-0025)
6 @ 5/4 x 4 x 17 1/2" WINDOW TRIM
(3-09-0026)
2 @ 5/4 x 4 x 17 1/2" ARCHED WINDOW TRIM
(3-09-0027)
1 @ 5/4 x 4 x 41 1/4" WINDOW TRIM (3-09-0029)
2 @ 5/4 x 4 x 21 1/2" WINDOW
TRIM (3-09-0028)
2 @ 5/4 x 4 x 23 1/2" DORMER
RUNNER (3-09-0033)
4 @ 5/4 x 6 x 50 3/4" ROOF FRAME TOP/BOTTOM (3-10-0010)
4 @ 5/4 x 6 x 60 7/8" ROOF FRAME SIDE (3-10-0011)
2 @ 5/4 x 6 x 9 1/2" PEAK
FACIA (3-10-0012)
2 @ 5/4 x 6 x 17 3/8" CHIMNEY SIDE
(3-10-0016)
2 @ 5/4 x 4 x 15 1/2" WINDOW VERTICAL
(3-09-0034)
359
358
1 @ 2 x 4 x 6 5/8" CHIMNEY BLOCK
(3-03-0054)
1 @ 2 x 4 x 24 1/4" RIGHT DORMER SUPPORT
(3-03-0053)
WOOD ROOF ADD-ON PARTS LIST
10

280
281
282
2 @ 4 x 4 x 93" MONKEY BAR SUPPORT LEG (3-06-0024)
1 @ 4 x 4 x 71" RIGHT MONKEY BAR ARM (3-06-0025)
1 @ 4 x 4 x 71" LEFT MONKEY BAR ARM (3-06-0026)
N10 N11 N33 N168
N13
N12
N25
N28
N26
N31 N30 N27
N15N18
N6
N5 N3
N29
N73
N14
1 @ SWING BEAM PLATE
(5-35-0092)
4 @ MONKEY BAR PLATE
(5-35-0093)
1 @ T-BRACKET
(5-35-0087)
1 @ BUBBLE PANEL
(5-42-0062)
6 @ REBAR STAKE
(5-47-0033)
1 @45
BRACKET
(5-35-0094)
4 @ LONG CHAIN (5-37-0027)
5 @ SHORT CHAIN (5-37-0026)
3 @ CASTLE LADDER HANDLE (5-33-0103)
1 @ TRAPEZE BAR
(5-40-0063)
4 @ PEAR QUICK LINK
(5-47-0045)
4 @ C-LINK
(5-47-0044)
9 @ SPRING CLIP
(5-47-0023)
2 @ SLING SWING
(5-40-0034)
2 @ TRAPEZE RING
(5-40-0056)
5/10 @ 21" PIPE (5-31-0137) 4/2 @ SAFETY HANDLE
(5-33-0102)
1 @ TIRE SWIVEL
(5-45-0008)
6 @ SWING HANGER
(5-45-0012)
2 @ SMALL BOLT CUP
(5-47-0035)
14 @ 3/8" BOLT CUP
(5-47-0043)
2 @120
BRACKET
(5-35-0044)
N38
1 @ SMALL 90 BRACKET
(5-35-0089)
N8
N170
2 @ 90 SWING BEAM
BRACKET (5-35-0095)
N171
MONKEY BAR PARTS LIST
PARTS IDENTIFICATION
11

N16
N174
N173
N172
N22
N20 N19
N83
1 @ TIRE (5-40-0047)
3 @ TTT ROD (5-41-0048)
2 @ TTT SPACER
(5-41-0048)
9 @ TTT CYLINDER
(5-41-0048)
16 @ ROCK
(5-42-0030)
1 @ RAINBOW PLAQUE
(5-42-0028)
1 @TELESCOPE
(5-41-0020)
1 @ SHIP'S WHEEL
(5-41-0021)
PARTS IDENTIFICATION
PARTS NOT SHOWN
1@ TARP (5-22-0238/5-22-0242)
1@ DOUBLE WALL SLIDE (5-44-0139)
3@ 14' ROPE (5-20-0279)
1@ 12' ROPE (5-20-0124)
1@ CHALKBOARD w/CHALK AND ERASER (5-20-0134)
1@ 4 Chain Tire Swing
1@ Half Bucket Swing (designed for children ages 3-5)
N41
N24
N2
N1
N167
N169
N17
Carnival Monkey Bar Hardware List
F/N# DESCRIPTION DIMENSION QTY
H3 Flat Washer 3/8" 10
H4 Flat Washer 1/2" 2
H11 Lock Washer 3/8" 10
H17 Standard Nut 3/8" 2
H28 Acorn Nut 3/8" 2
H30 Round Pallet Nut 3/8" 8
H55 Carriage Bolt 3/8" x 6" 2
H128 Hex Bolt 3/8" x 3" 8
H167 Phillips Pan Head Tap Screw #14 x 2" 4
12

NOTE: EXTRA HARDWARE IS INCLUDED IN THE BAGS.
NOT ALL HARDWARE WILL BE USED TO COMPLETE THE INSTALLATION.
Carnival Castle Base Hardware List
F/N# DESCRIPTION DIMENSION QTY
H1 Flat Washer 1/4"
21
H3 Flat Washer 3/8"
60
H4 Flat Washer 1/2"
17
H5 Flat Washer 3/4"
2
H7 SAE Washer 1/4"
68
H11 Lock Washer 3/8"
40
H12 Lock Washer 1/2"
2
H14 Fender Washer 3/8"
6
H17 Standard Nut 3/8"
16
H18 Standard Nut 1/2"
2
H24 Nylock Nut 3/8"
15
H28 Acorn Nut 3/8"
28
H29 Acorn Nut 1/2"
2
H30 Round Pallet Nut 3/8"
6
H32 4 Prong T-Nut 1/4"
32
H34 4 Prong T-Nut 3/8"
8
H50 Carriage Bolt 3/8" x 3 1/2"
2
H55 Carriage Bolt 3/8" x 6"
10
H56 Carriage Bolt 3/8" x 6 1/2"
2
H60 Carriage Bolt 3/8" x 8 1/2"
1
H64 Carriage Bolt 1/2" x 3"
2
H93 Lag Bolt 1/4" x 2"
6
H100 Lag Bolt 1/4" x 4 1/2"
4
H108 Lag Bolt 5/16" x 3"
19
H116 Lag Bolt 3/8" x 3 1/2"
6
H117 Lag Bolt 3/8" x 4"
8
H119 Lag Bolt 3/8" x 5"
5
H126 Hex Bolt 3/8" x 2"
2
H129 Hex Bolt 3/8" x 3 1/2"
3
H132 Hex Bolt 3/8" x 5"
8
H135 Hex Bolt 3/8" x 6 1/2"
12
H139 Hex Bolt 3/8" x 9"
1
H140 Hex Bolt 3/8" x 10"
1
H194 Phillips Wood Screw #8 x 1 1/4"
72
H152 Phillips Wood Screw #8 x 1 1/2"
114
H154 Phillips Wood Screw #8 x 2"
16
H155 Phillips Wood Screw #8 x 2 1/2"
80
H191 Phillips Wood Screw #8 x 3"
16
H158 Phillips Pan Head Tap Screw #10 x 1 1/2"
8
H164 Phillips Pan Head Tap Screw #14 x 1"
24
H167 Phillips Pan Head Tap Screw #14 x 2"
14
H192 Phillips Pan Head Machine Screw 1/4" x 1 1/2"
32
H183 Snap Screw #10 x 1"
8
H184 Eye Bolt 3/8" x 3"
3
Carnival Castle Wood Roof Hardware List
F/N# DESCRIPTION DIMENSION QTY
H1 Flat Washer 1/4" 8
H3 Flat Washer 3/8" 4
H11 Lock Washer 3/8" 4
H34 4 Prong T-Nut 3/8" 4
H108 Lag Bolt 5/16" x 3" 8
H130 Hex Bolt 3/8" x 4" 4
H194 Phillips Wood Screw #8 x 1 1/4" 278
H152 Phillips Wood Screw #8 x 1 1/2" 134
H154 Phillips Wood Screw #8 x 2" 24
13

0
1
2
3
4
5
6
7
8
9
H191
H152
H158
H167
H164
H14
H12
H5
H7
H1
H3
H4
H9
H11
H17
H28
H24
H32
H34
H30
H18
H29
H194
H154
H155
H157
H188
14
Hardware for Assembly

0
1
2
3
4
5
6
7
8
9
H60
H128
H56
H126
H50
H129
H130
H55
H135
H132
Hardware for Assembly
*NOTE: Thread length may vary from what is pictured.
15

0
1
2
3
4
5
6
7
8
9
H93
H100
H108
H116
H117
H119
H192
H64
H139
H139 is 3/8" x 9"
H140 is 3/8" x 10"
H140
*NOTE: Thread length may vary from what is pictured.
Hardware for Assembly
7/16" Deep Well Socket
1/2" Deep Well Socket
9/16" Deep Well Socket
9/16" Box Wrench
8' Step Ladder
Safety Glasses
Adult Helper
36" Bar Clamp (optional)
Electric Impact Gun or 1/4"
and 3/8" Ratchet
1/8" Drill Bit
1/4" Drill Bit
5/16" Drill Bit
9/16" Drill Bit
Torque Wrench
Crescent Wrench
Tape Measure
Carpenters Level
Carpenters Square
3-pound Sledge Hammer
Claw Hammer
Wood Clamp
Standard or Cordless Drill
with #2 & #3 Phillips Bits
TOOLS REQUIRED FOR ASSEMBLY
16

77
78
77
82
81
N171
86
N29
N15
N31
N13
N246
N26
N14
N18
N30
N16
N12
N12
N6
274
269
268
276
277
293
N3
303
N41
302
291
354
N168
N172
279
N19
271
255
256
200
263
264
265
N5
257
PARTS IDENTIFICATION
17

N24
N3
280
280
N5
282
281
N11
275
278
269
270
286 285
284
283
273
N5
N156
382 379
378
329 306 307
364
365
366
367
368
369
370 358
357
355
356
362
363
245
259
246
247
383
298 299
253
360
260
252
251 250
248 262
200 272
308
381
PARTS IDENTIFICATION
18

20 1/2"
19 1/2"
384
N3 277
SURFACES
FLUSH
276
277
24"
276
N3
277
8 7/16"
8 7/16"
18"
9 9/16"
276
277
LADDER
BOTTOMS
INSET A
1. Place Castle Rung Ladder Leg (277) on a flat surface with the pipe holes facing up. Remove any
objects from underneath the Castle Rung Ladder Leg to prevent scarring of the wood.
*NOTE: Do not directly hit the wood or the Ladder Pipes (N3) with a hammer. Use Pipe
Block (384) with a 3-pound (or larger) sledge hammer.
2. Using Pipe Block (384) and a sledge hammer, pound each Ladder Pipe (N3) into the Castle Rung
Ladder Leg (277) . Pound the inside three Ladder Pipes (N3) into the wood so they protrude
approximately 19 1/2" from the wood and the outside two Ladder Pipes (N3) approximately 20 1/2"
from the wood.
*NOTE: Ensure Middle Step/Rung Ladder Leg (276) is oriented properly (as shown in INSET
A). The centers of the first rung holes from Ladder Bottoms should measure 8 7/16".
*SUGGESTION: Use a bar clamp to hold ladder together while pounding on second ladder leg.
3. Position Middle Step/Rung Ladder Leg (276) on top of the installed Ladder Pipes (N3) . Using a
sledge hammer, pound the Middle Step/Rung Ladder Leg (276) onto the Ladder Pipes (N3) .
When properly assembled, the ladder should have a width of 24" .
19
Step 1
Rung Ladder Assembly