SportsPlay Ray 911-110 User manual

Page 1
800-727-8180 www.sportsplayinc.com
911-110
Model Ray

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INDEX
INDEX...................................................................................... 2
Tool and Material Checklist...................................................... 3
Introduction............................................................................... 4
Quick Guide.............................................................................. 5
Safety Surfacing/Fall Heights................................................... 7
Punch List ................................................................................. 9
Top Down View...................................................................... 11
Footing Diagram..................................................................... 12
Post Installation....................................................................... 13
Deck and Pipe Clamp Installation........................................... 15
Deck Clamp 903-002................................................... 15
Pipe Clamp 903-001....................................................... 15
Deck Clamp Plan:............................................................... 16
Pipe Clamp Plan:................................................................. 17
Deck Installation..................................................................... 19
Square Deck........................................................................ 19
Triangle Deck...................................................................... 19
Deck Plan:........................................................................... 20
Guard Wall 902-135-W................................................... 21
Guard Wall Plan:................................................................. 22
Steering Wheel 902-114................................................ 23
Steering Wheel Plan:........................................................... 24
Tic Tac Toe Panel 902-121............................................... 25
Tic Tac Toe Panel Plan:...................................................... 26
Vertical Climber...................................................................... 27
Vertical Climber Plan: ........................................................ 28
Corkscrew Climber 902-133-3, -4, -5................................. 29
Corkscrew Climber Plan:.................................................... 30
Double Wall Straight Slide 902-213, 4, 5.......................... 31
Double Wall Straight Slide Plan:........................................ 32
Pyramid Roof 902-275................................................... 33
Pyramid Roof Plan:............................................................. 34
Label Installation .................................................................... 35
Top of Surfacing Label....................................................... 35
Warning Label .................................................................... 35
Manufacturer Label............................................................. 35
Trouble Shooting .................................................................... 36
Safety Checklist...................................................................... 37
Photo Appendix ...................................................................... 38
Maintenance Checklist............................................................ 41

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Tool and Material Checklist
• To dig holes, the best method is a tractor with an auger.
Use a 12” auger bit. No matter what you use, there will
be a considerable amount of hand digging as well
• Shovels, long handled spades
• Post hole diggers
• Wheelbarrows
• Large construction bar (generally 5’ long).
• Spray paint, to mark ground holes
• Pry bar
• Claw hammers
• Large dead-blow rubber hammers
• Small (3lb) Sledgehammer, to use in blocking the posts
• 7/32”, 3/6”, 1/8” Allen wrenches: These are very
important. Several different types are helpful (socket
style, small “L” arm, wrench styles etc.)
• Vise grips, large, regular and needle-nose
• 3/4” and 1/2” and 9/16” sockets, both 1/2” and 3/8”
drives
• 6’ and 8’ stepladders, strong ones
• Extension cords (also duplexes to run more than one
cord)
• 1/2” drill and 3/8” drill
• 1/2” and 1/2” drill bits and 1/2” spade bits
• Levels: magnetic torpedo, 4’ long etc. (as many as
possible)
• Shims and blocks from scrap lumber and a saw to cut
sizes on site
• Small, skinny, flat shims are helpful in raising posts etc.
2” by 4” and 2” by 6” and Plywood are also helpful
• Pencils and markers
• String line
• Bar clamp 4’
• Sometimes bracing material is helpful (2” x 4” x 6’
studs with sturdy lag bolt/nut combinations)
• Files, sandpaper, wood scraps
• Stones
• Cement
• Surfacing
• One brick per post

Page 4
Introduction
BEFORE STARTING INSTALLATION OF YOUR
PLAYGROUND, PLEASE READ INSTRUCTIONS
THOROUGHLY.
SITE REQUIREMENTS:
The Playground system is designed to suit a level site. Should
there be any falls or slopes on the site; care should be taken to
accommodate the entry and exit points and to maintain the
correct height. There should not be more than 3” of drop in
grade per every 10’
The site must be inspected for adverse conditions:
All sites must be checked for existing utilities such as
electricity, gas, water or any other underground hazards. 1-
800-DIG-RITE is the number to call to have the services
located.
1.
2. Roots, rocks, or other natural obstacles that may pose as
a trip hazard.
3. Poor drainage areas.
4. Broken glass or foreign objects around building site.
MAINTENANCE:
As an owner, it is most important that you are aware of your
responsibility to insure safe use of your new equipment. It is
necessary to install equipment correctly according to the
installation instructions provided and inspect the equipment at
regular intervals. During inspection, if any part is found
damaged or excessively worn, equipment should immediately
be put out of service while the part is replaced. Lack of
maintenance will result in premature wear, reduced life
expectancy, and possible failure that might result in injury.
All SportsPlay Equipment play events have been engineered to
meet all applicable safety guidelines, but if installed
improperly, these problems may occur:
• Entrapment gaps (between 3 1/2” and 9”}
• String Entanglements
• Protrusions
Make sure that any bolt end that protrudes more than 2 threads
past the face of the nut is trimmed and deburred smoothly.
Always double-check your work.
Installation must adhere to the manufacturers assembly manual
and all other applicable safety guidelines.
PLAY AREA:
The area immediately above and around the play structure must
be free of any obstructions such as:
• Trees
• Other Play Equipment
• Buildings
• Overhead Power lines
Make sure the play area has all the required safety
surfacing and the minimum fall zones as required by the
safety guidelines. These guidelines can be found at
www.cpsc.gov.
CHILDREN MUST BE SUPERVISED AT ALL TIMES.
No playground is safe without adult supervision!

Page 5
Quick Guide
SITE – Make sure the area of installation is relatively level,
free of obstacles and underground utilities. If a slope exists,
care must be taken to accommodate entry and exit areas to
insure they maintain the correct heights. Call 1-800-DIG-RITE
to have a technician check the area for underground utilities.
This service is free.
MATERIAL INVENTORY – Locate your Component
Checklist and the 2d top down drawing included in the
instructions. Use both to identify, inventory and best position
the parts around the perimeter of the area. If you find damaged
or parts missing, contact your SportsPlay Distributor
immediately.
INSTRUCTIONS – Thoroughly read the instruction booklet
BEFORE beginning the installation. Pay special attention to
the pages describing post and deck installation. These are the
‘bones’ of your playground. If they are not properly installed,
the remaining events will not install correctly. KEEP THESE
INSTRUCTIONS ON FILE.
TOOLS – Locate the Tools Checklist in the instructions.
Make sure all necessary tools are available at installation time.
If you are using volunteers, send a note to them that includes
the tool list. You may be able to borrow most items instead of
renting.
SUPPLIES – Set your installation date and order supplies
from your local building center. You will need some flat
concrete stones for blocking holes, some scrap lumber for
bracing and cement. You can figure about 2 80# bags per hole.
DECK LAYOUT – Find the grid drawing in the instruction
booklet. Decide which way to orient the structure. ALL fall
zone measurements MUST be accommodated. Locate the
lowest deck on the drawing. You can start laying out the
structure by placing the lowest deck on the ground and then
double check your measurements. Measure twice, install once!
Consult the instruction booklet for post and deck installation
instructions.
BRACING – As the decks and kick plates are installed, be
sure to level the posts and place braces in the holes to keep
them from shifting. Periodically, plumb and level all posts as
you work your way around the playground.
COMPONENT INSTALLATION – Consult the instruction
booklet for separate installation instructions for each
component on your playground. Begin installing from the
lowest deck in a clockwise rotation around the structure back
around to the starting deck. Tighten panels as you go, making
sure to plumb and level posts.
VISUAL INSPECTION – After all components are installed
and tight, do a visual inspection to ensure the panels and posts
are level, in the proper place, and look good with respect to one
another. Once satisfied, you are ready for concrete.

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CONCRETE – Mix the concrete according to the directions.
DO NOT mix directly in the hole. Fill each hole to within 2
inches of the original surface. Crown for drainage, and cure 48
hours.
SECURE AREA – Fence off or lock area to insure that NO
ONE can play on the playground until it is completely finished.
You may consider contacting local law enforcement to inform
them of the new installation and ask them to check the area
frequently during the night.
BACKFILL AND CLEANUP – 48 hours after pouring
cement, backfill all of the holes with dirt to the original ground
level and make sure the area is free of any tools, hardware, or
sharp objects.
SURFACING – Use the chart on page 8 to decide how much
safety surfacing is required. Before spreading loose fill
surfacing, be sure to install a weed barrier outside the fall zone
dimension, then spread the safety surfacing.
LAST THING – Make one more tour around the playground
and physically make sure all hardware is tight.
OPEN FOR PLAY – After the safety surfacing is installed and the
hardware has been checked for tightness, your playground is ready for
play.
MAINTENANCE - Consult your instruction booklet for the
maintenance checklist. Schedule and complete periodic
maintenance checks of the entire playground. If any hardware
is worn, or any item missing or broken, close the playground
and contact your SportsPlay distributor for replacement parts.
Check resilient surfacing depths, move or add additional
surfacing if necessary. Make sure the playground area remains
free of obstacles, broken glass or other sharp objects.

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Safety Surfacing/Fall Heights
You must consider the type of safety surfacing you will use
before beginning the installation process. There are two
general types, organic/loose fill or synthetic unitary. Both
materials have advantages and disadvantages and it is likely
that your client’s budget will dictate the material of choice.
Always have all options available as product quality and long-
term performance may cause your client to reevaluate their
original budget.
When installing a unitary safety surfacing material such as
rubber mats or poured-in-place, you will need to pour a
concrete slab so that the rubber material can be secured. This
type of product cannot be placed on dirt.
If a loose fill surface such as wood chips is selected, you will
need to consider containment borders. There are many
products to choose from including hard plastic and natural
products such as wood. Creosoted railroad ties are NOT
recommended. Loose fill materials like wood chips are easily
displaced, so 12” deep is generally satisfactory. Also
remember that loose fill will compress with repeated use.
Weed mat: Some use a landscaping fabric material that allows
drainage but prevents weed growth. Weed mats are installed
after the structure is installed but before the resilient surfacing
is installed.
Borders: Building borders above ground, below grade, or on
grade depends upon the area in which you live. Assuming you
must use 12” of resilient surfacing, there are three basic types
of installation:
1. 12” below existing grade
2. 6” below and 6” above existing grade
3. 12” above existing grade
The tallest deck on the unit generally defines the maximum fall
height of a structure. If upper body equipment (horizontal
ladder) is attached, the fall height is then the distance from the
highest part of the equipment to the protective surfacing. Refer
to the Top Down View to determine the maximum fall height.
Since the structure will be installed at dirt grade, the height of
the resilient surfacing must be determined and factored into the
height of installation of decks. For example, if the resilient
surfacing will be 12” deep, a 3’ deck height will actually install
at 4’. When the structure is completed and the surfacing is
installed, the deck then will be 3’ above the level of the
resilient surfacing.

Page 8
Safety Surfacing Chart
Table – Critical heights (in feet) of Tested Materials
These directions are written based upon a depth of 12” of
resilient surfacing.
Do not forget to calculate the compressed resilient surfacing
depth needed and adjust your “dirt grade height” accordingly.
Chart taken from The Handbook for Public Playground Safety
written by the U.S. Consumer Product Safety Commission
(CPSC) page 5 (www.cpsc.gov).
Material Uncompressed
Depths Compressed Depths
6” 9” 12” 9 “
Wood
Chips 4 10 11 10
Double
Shredded
Bark Mulch
6 10 11 7
Engineered
Wood
Fibers
6 7 >12 6
Fine Sand 5 5 9 5
Course
Sand 5 5 6 4
Fine Gravel 6 7 10 6
Medium
Gravel 5 5 6 5
Shredded
Tires 10- 12 N/A N/A N/A

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Punch List
Step 1: Layout
1. Lay square deck on ground in the desired location and
measure from all corners to insure there is adequate
room. (Refer to Grid Drawing pg. 11)
2. Most installers usually like to orientate the playground
so that the entry point of the playground is facing either
the sidewalk or the direction from which the children
are coming.
Step 2: Holes
1. Mark the locations of all four post holes by using the
center point of each deck corner and marking them with
paint or a wooden stake.
2. After the holes are marked, move the deck out of the
digging area and dig all four holes per the footing
drawing on page 12.
3. Fill or dig the depth of 1 main hole to what is required;
this hole will be used to get the other three holes the
same depth in reference to each other. Make sure the
hole is flat and tamped solid, then place a small piece of
plywood or brick in the bottom. You must take this in
account when determining the hole depth.
4. Now, if possible, use a transit to maintain the same hole
depth on the remaining three holes, if you don’t have
access to a transit, then park a line on the first post
about two inches above the dirt level. Then measure up
from the bottom of the post to this mark and mark a line
on the other three posts at the same distance. Now use
a four-foot level across to each line, raising or lowering
as necessary to make the lines level. Repeat this for the
remaining two posts.
Step 3: Deck and Post Installation
1. Measure 36” plus the amount of safety surfacing you
are planning on using (example: 36” + 12” = 48” from
the existing ground level). Make a mark on the first
post at this measurement and then measure from the
bottom of post to this mark and make a mark on the
remaining three posts at the same measurement.
2. Install a deck clamp per instruction page 16. Tighten
all hardware.
3. Now make sure that you have two other helpers and the
required deck clamp hardware.
4. Place all four posts into the holes and let them rest on
the hole edges. Now install the deck on two of the deck
clamps and install hardware down through the deck and
clamp and install the locknut on the bottom. Do not
tighten at this point.
5. Next place the other two posts on the deck and install
the hardware.
6. It may be necessary to brace the deck and posts with
lumber to make sure they stay in place and level. Level
all four posts and tighten hardware. Also make sure the
deck was installed level.
Step 4 – Component Installation
1. Begin by installing the corkscrew climber per
instructions on page 29.

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2. Next install the double wall slide per instructions on
page 31. Make sure water drains out of the slide bed
and the slide guard is level, then tighten.
3. Now install the Guard Wall and Wheel per instructions
page 21 and 23. Level and tighten.
4. Now install the Tic Tac Toe Panel per instructions on
page 25.
5. Install the Vertical climber per instructions on page 27.
6. Install the Pyramid roof per instructions on page 33.
Step 5: Concrete
1. Once all components and posts are tight and level, you
may concrete. A good rule of thumb is two 80 lb. bags
of concrete per hole. Do not “dry bag” the concrete,
always mix per instructions on concrete bag. Be sure to
leave concrete about 2” from the top of the ground to
allow backfill.
2. Be sure that all splattered concrete is washed off of the
posts and components while it is still wet.
3. Block off installation area for at least 48 hours.
Step 6: Final after 48 hours
1. Return in 2 days to backfill concrete, drill and install
drive (roll) pins per instructions, and install safety
surfacing.
2. Inspect all components to insure the hardware is tight
and all panels are level.
3. Make sure all tools and dropped hardware are removed
from play area.
4. Open the playground.

Page 11
Top Down View
Actual scale drawings are included at the end of these
instructions.

Page 12
Footing Diagram

Page 13
Post Installation
Footing size may vary due to local soil and weather conditions.
Base of footing MUST be below the frost line.
• Dig holes straight down, with a flat bottom and 12”
wide making sure to dig holes wide and not cone
shaped.
• Hole depths are 22” deep (this depth changes slightly
with grade).
• Place a brick in the bottom of the hole.
• Post is placed on top of the brick.
• If the bottom is not flat and roomy, there will be no
room to adjust. It is much easier to have too much
room rather than not enough.
• You can dig by hand using a posthole digger, but a
tractor with a 12” auger will make the task much easier.
• Post tops should be level with one another.
• USE A LONG, HEAVY CONSTRUCTION BAR to
adjust levels of posts, legs, etc. DO NOT try to level by
pushing posts at shoulder or waist length. Carefully
bump the posts at the bottom IN THE DIRECTION
YOU WANT THE POST TO GO.
• Mark holes and dig by laying the deck on ground and
using it as “jig”. Place (4) deck clamps, one per corner,
spray paint through middle of clamp onto ground. This
marks where the centers of the postholes should be.
• Remove the deck and clamps from the area.
• Dig the (4) holes 22” deep and 12” wide. Holes are
straight down and flat-bottomed. Install 10” diameter
plywood in hole bottoms and place a brick in the
bottom of the hole.
• Use a marker to mark 22” from bottom of posts. Use
these marks so you can run a 4’ level across marks to
make sure the tops of the posts are equal to each other.
If line marks are on bubble, then post tops should be on
bubble to each other.
• Install the red plastic end caps on post bottoms.
• Since your holes are 12” diameter and posts are
centered in holes you have approx. 3 1/2” all around the
post.
• Block the posts into center of holes when posts are on
bubble. Use scrap lumber and wedges to solidify the
posts in their holes as you level the posts. Re-blocking
may be necessary at times in order to achieve level.
You may also have to widen your holes if they are not
dug on center.
Top down view of post set into hole:

Page 14
Side view of installed post

Page 15
Deck and Pipe Clamp Installation
Deck Clamp 903-002
Item
# Part # Part Description Quantity
1 105-025 Clamp half FRONT 1
2 105-026 Clamp half BACK 1
3 116-600 1/2” x 2 1/2” Button Head
Bolt 1
4 196-550 Roll Pin 1/4” x 1 3/4” 1
5 236-601 3/8” T-Nut 1
6 196-555 Roll Pin 1/4” x 3/4” 1
7 126-703 3/8” x 1” Button Head Bolt 1
8 226-801 1/2” Lock Nut 1
9 316-801 1/2” Washer 2
Pipe Clamp 903-001
Item
# Part # Part Description Quantity
1 904-002 Clamp half – BACK 1
2 904-001 Clamp half – FRONT 1
3 126-706 3/8” x 1 3/4” Button Head Bolt 2
4 196-807 Socket Set Screw 3/8” x 3/8” 1
5 236-601 T-Nut 3/8” 2
6 196-555 Roll Pin 1/4” x 3/4” 1

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Deck Clamp Plan:
The deck clamps connect to the main upright posts according
to the deck height(s) located on the Top Down View.
INSTRUCTIONS:
1. Install the deck clamps to the center of the deck
corners. If clamps are off center, then the line of posts
will not be straight and the components will not connect
properly.
2. Raise the deck to the proper level according to the deck
height found on the Top Down View.
3. Hand tighten the button head bolt. Do not over tighten
because the post may ‘swing’.
4. Decks attach to the clamps using 1/2” x 2 1/4” Button
head bolts, washer on top and bottom with 1/2” lock
nuts. Connect the deck bolt firmly.
5. Check the deck and all four posts to insure they are
level and the deck is at the proper height.
6. Once the deck and all four posts are level and the deck
is at the proper height, tighten the clamp onto the post.
7. Install Roll Pins
When the playground has been built and there are no more
adjustments, drill through all of the clamps (through pre-drilled
1/4” drill holes in clamps) and the 5” O.D. posts. Use a sharp
1/4” metal drill bit to drill a straight hole. Do not egg out the
holes. Then tap a 3/4” roll pin through clamp into post so that
the pin is flush with the clamp. Do not allow pins to protrude.
If a pin has been installed but a clamp or component has to be
moved, the pin can be knocked through into post.
IMPORTANT: Extra roll pins can be installed through certain
high traffic clamp applications such as firepoles, roof clamps,
handholds, etc. Finally smooth down any drill holes etc., with
steel wool or a file.
SPECIFICATIONS:
Event: Clamps shall be 606ITS aluminum fastener for 5” OD
posts weighing 2.21 lbs.
Paint shall be electrostatically applied oven cured powdercoat.
Hardware: Stainless Steel tamper resistant
MAINTENANCE:
Touch up any marred paint surfaces.
Periodically check hardware for integrity and tightness.

Page 17
Pipe Clamp Plan:
The pipe clamps connect to the main upright posts according to
the height of the events found on the Top Down View.
INSTRUCTIONS:
There are two ways to install the clamps:
1. Pre-install the clamp to the post first, then slide the 1
3/8” O.D. pipe into the clamp.
2. Install the clamp over the 1 3/8” pipe first, and then
install the clamp to the post.
You will do both of these applications, depending on the
circumstances.
1. Clamp is installed to post first, then 1 3/8” O.D. pipe
moves into clamp.
2. Install clamp to pipe first, then to post. Fit clamp onto
the pipe, and install the clamp “sideways” over the post.
You may have to assert some pressure. MAKE SURE
PIPES ARE ALL THE WAY INTO CLAMPS
BEFORE INSTALLING ONTO POSTS. (2 1/4” end of
pipe goes inside clamp) Use rubber hammer for clamps.
You can use a marker to mark the location of clamps when pre-
installing posts. If a pipe clamp is close to another clamp or a
deck etc. it may be necessary to pre-tighten the set screw to
clamp, then move clamp into position. For convenience of
installing button head bolts, it is necessary that the bolt heads
face outward.
If the clamp is crooked to the pipe, and the pipe WILL NOT be
able to enter the clamp. Sometimes, you can coax the clamp
onto the pipe with a rubber hammer. If that will not work, take
clamp off and install it “sideways”, placing it on the pipe first
and then onto the post. Pipes enter into clamps 2 1/4” deep.
Components like walls, vertical climbers, ladder ends, etc. are
all 48” long, and the pipe ends have to go straight into the
clamps or the connection will not work. If you force a clamp it
can break!
All of our components such as walls, climbers, horizontal
ladders, arch walls etc. are 48” wide, and clamp to the middle
of the posts. That means that these components are centered
onto the posts at 48” on center.
There is up to 4” of extra room in the pipe clamp cavities, 2” to
the left and 2” to the right. This means that it is possible to be
either too far left or right of center. Keep in mind that all
COMPONENTS HAVE TO BE CENTERED, that the left and
right are inserted equally into clamps!
When the playground has been built and there are no more
adjustments, drill through all of the clamps (through pre-drilled
1/4” drill holes in clamps) and the 5” O.D. posts. Use a sharp
1/4” metal drill bit to drill a straight hole. Do not egg out the
holes. Then tap a 3/4” roll pin through clamp into post so that
the pin is flush with the clamp. Do not allow pins to protrude.
If a pin has been installed but a clamp or component has to be
moved, the pin can be knocked through into post.
Extra roll pins can be installed through certain high traffic
clamp applications such as firepoles, roof clamps, handholds,

Page 18
etc. Finally smooth down any drill holes etc., with steel wool
or a file.
SPECIFICATIONS:
Event: Clamps shall be 606ITS aluminum fastener for 5” OD
posts weighing 2.21 lbs.
Paint shall be elecrtostatically applied oven cured powdercoat.
Hardware: Stainless Steel tamper resistant
MAINTENANCE:
Touch up any marred paint surfaces.
Periodically check hardware for integrity and tightness.

Page 19
Deck Installation
Square Deck
Item
# Part # Part Description Quantity
1 905-705 Square Deck 1
2 903-002 Deck Clamp Assembly 4
4 316-801 1/2” Washer 8
5 226-801 1/2” Lock Nut 4
6 126-703 3/8” x 1” Button Head Bolt 4
Triangle Deck
Item
# Part # Part Description Quantity
2 903-002 Deck Clamp Assembly 3
3 905-710 Triangle Deck 1
4 316-801 1/2” Washer 6
5 226-801 1/2” Lock Nut 3
6 126-703 3/8” x 1” Button Head Bolt 3

Page 20
Deck Plan:
The deck(s) connect to the main upright posts according to the
specifications found on the Top Down View.
INSTRUCTIONS:
There are two methods:
The BEST method is to make a table or stand to place your
deck on at the required deck height. The table will stabilize the
deck so you can level it.
You can make a table from sawhorses.
Deck stand or table holds deck while you build around it.
Blocks stabilize the posts while table stabilizes the deck.
The second method is to pre-install the (4) deck clamps so that
there is 42 1/4” between the holes in the deck clamps.
Use a level and a marker to make sure the clamps are level to
each other.
Place deck onto clamps and bolt.
This method works but is less stable than the first method. The
deck and posts will stabilize more as you add components
Pre-install deck clamps and level.
SPECIFICATIONS:
Event: Steel Deck shall be constructed of #12 gage perforated
steel, welded to 2 1/2” x 2” by 18” angle frame, 1/4” endplates,
center-bracing, plastisol coated and oven cured.
Paint: Oven cured plastisol
Hardware: Stainless Steel tamper resistant
MAINTENANCE:
Touch up any marred paint surfaces.
Periodically check hardware for integrity and tightness.