Gorilla Playsets Congo Climber II User Manual

Congo Climber II

2007

Copyright © 2007 Gorilla Playsets, Inc.

All Rights Reserved

Made in the U.S.A.

Gorilla Playsets, Inc.

 190 Etowah Industrial Ct.  Canton, GA 30114  [phone]

IMPORTANT INFORMATION:

IF YOU HAVE MISSING OR DAMAGED PARTS
OR NEED ASSISTANCE ASSEMBLING, PLEASE

CALL gorilla playsets MANUFACTURING
DIRECT.

[phone]

FACTORY HOURS – MON.–FRI., 9AM-6PM EST

DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT
THE RETAILER DIRECT. THE RETAILER DOES NOT STOCK
COMPONENTS.

CONTACT INFO:
Gorilla Playsets, Inc.

190 Etowah Industrial Ct.
Canton, GA 30114
Tel. [phone]
Fax. [phone]
[e-mail]

2

Warranty and Safety Guidelines………………………………………….….……… 5-7

Kit Contents and Tool List…………..………………………………………………. …8

Site Plan Dimensions…………………………………………………………………….9

Missing or Damaged Items Replacement Procedure...…………….……….………...10

Hardware, lumber, and accessories…………………………………………………13-21

Framing the playset...…………………………………………………..…….… steps 1-7

Mounting sandbox and lower panel boards…..…………………………..… steps 8-11

Constructing deck and upper panel boards.….……..………………..…… steps 12-17

Attaching center posts…………………………..…..……………..………… steps 18-20

Building and mounting ground ladder….…………………….……….…… steps 21-22

Adding wall slats to panels………….……...…………………………..…… steps 23-25

Finishing and installing rope ladder……….....…………………………..… steps 26-27

Securing supports then adding picnic table and benches………….……… steps 28-31

Constructing swingbeam and add swing hardware……….……….……… steps 32-39

Adding vinyl tarp……………………………………………………..……….… steps 40

Mounting slide………..……………………………………….………………… steps 41

Attaching swings...……………………………………………….……………… steps 42

Constructing rockwall and securing to fort………….……………..……… steps 43-45

Constructing tire swing beam and add tire swing hardware…………...….steps 46-51

Installing angle supports…………………………………………………………..step 52

Customer Registration Card………………………......…….……………..….……… 75

Gorilla Climber II

TABLE OF CONTENTS

3

Thank you for choosing gorilla playsets® for your new backyard playground!

We’ve included everything you need except tools, to build your very own professional
looking playset. When complete, your new playset should far exceed the quality of playset kits
from other build-your-own companies. Our engineers and design team have over 30 years of
playground experience. What we’ve developed is a playset that doesn’t compromise quality for
simplicity. Yet you’ll appreciate how quick and easy construction really is! Our playset kits are
designed for children ages 3 to 12. gorilla playsets® believes every child should have a
playset and with our kits they can! You can rest assured your new playset is safe, durable and
designed to hold up to the elements. As parents ourselves we know how important the
security and well being of our children is and this shows in all of our products.

Each playset features our step-by-step 3D illustrated manual, patented powder coated
swing beam bracket, heavy-duty swing belts with chains, slide(s), accessories, plus all the
required hardware and pre-milled lumber.

Quality Lumber

At Gorilla Playsets, we use only the finest, hand selected lumber available. Whether
you choose a playset made from our Premium Preserved Pine, our Beautiful California
Redwood or our Western Red Cedar, you can be assured that our lumber is strong, durable,
and conforms to the national standards for use in children’s play equipment. It’s this quality
that allows us to offer a 10 year warranty on the lumber used in our play sets.

Premium Preserved Pine

Our Premium Preserved Pine is double kiln dried. We utilize this process to minimize
shrinkage, warping, and cupping. Because our pine has been “pre-shrunk”, the hardware
used to assemble your playset will hold tight, stay tight, and won’t loosen or weaken. Our
preserved pine is clean, odorless, non-staining, and non-irritating to humans, animals, or
plants. Gorilla’s Preserved Pine uses one of the only exterior wood preservation systems that
is EPA approved. Our pine lumber is preserved with a preservative system containing copper
and quaternary compounds to protect against termite attack and fungal decay. Our Premium
Preserved Pine can withstand harsh weather conditions and is effective for decades, Making
Gorilla Playsets the best choice in pine lumber built swing sets.

California Redwood and Western Red Cedar*

Our Beautiful California Redwood and Western Red Cedar play sets are a natural
alternative to preserved lumber. California Redwood naturally resists decay caused by the
environment or by insect infestation while Western Red Cedar is a preferred wood for
purposes where an attractive appearance and resistance to weather is important. All
California Redwood and Western Red Cedar Gorilla Playsets receive a factory stain and sealant
process. To maintain this aesthetic appeal, it is recommended that you seal your redwood and
cedar play set once per year.

*Playnation reserves the right to substitute Western Red Cedar with other species of
similar characteristics due to market availability.

4

Limited Manufacturers Warranty

gorilla playsets® ("Gorilla") warrants this product to be free from defects in workmanship
and materials, under normal use and conditions, for a period of 10 years for structural wood
components and one year for all other components (i.e., hardware, plastics, tarps, rope
ladder, etc.). Cosmetic defects that do not affect the structural integrity of the product, or
natural defects of wood such as warping, checking or any other physical properties of wood
that do not present a safety hazard, are not covered by this warranty.

gorilla playsets® will repair or, at its discretion, replace any part within the stated
warranty period that is defective in workmanship or materials. This decision is subject to
verification of the defect upon delivery of the defective part to gorilla playsets® at 190
Etowah Industrial Court, Canton, Georgia 30114. Any part(s) returned to gorilla playsets®
must include proof and date of purchase.

This warranty is valid only if the product is used for the purpose for which it was designed
and installed at a residential, single-family dwelling. This warranty is void if the product is put
to commercial or institutional use. This warranty does not cover (a) products which have been
damaged by negligence, natural disasters, or accident by improper use, or which have been
modified or repaired by unauthorized persons, (b) the cost of labor, or (c) the cost of shipping
the product, any part, or any replacement product or part.

This warranty is valid only in the United States of America, is non-transferable and does
not extend to the owners of the product subsequent to the original purchaser. gorilla
playsets® disclaims all other representations and warranties of any kind, express, implied,
statutory or otherwise, including the implied warranties of merchantability and fitness for a
particular purpose. gorilla playsets® will not be liable for any incidental or consequential
damages. Some states do not allow limitations on implied warranties or exclusion of incidental
or consequential damages, so these restrictions may not be applicable to you. This warranty
gives you specific legal rights. You may also have other rights that vary from state to state.

IMPORTANT SAFETY GUIDELINES
This product is intended for residential use only and not intended for use in any public
setting. A safety surface such as mulch or recycled tire should be used under the play set to
prevent injury from falls. Also a 6 foot safety zone should be used around the entire playset.
As with any home project, good judgment and respect for power tools will greatly reduce
the risk of injury. gorilla playsets® recommends you follow all tool manufacturers’ safety
guidelines. Always wear eye protection and safety gloves to prevent injury. In several phases
of construction two people may be required for lifting and securing of lumber. While playset is
being constructed, please keep children off the equipment until the project is complete. Bolts
and screw heads should be checked regularly for tightness. The ground ladder, rope ladder,
slide, swings and other areas where children spend a majority of their playtime should be
checked more frequently.
gorilla playsets® shall not be liable for incidental, indirect or consequential damages or
injuries that result from the building and/or playing on our playsets. Adult supervision is
recommended anytime a playset is being used.

5

Safety and Maintenance Tips for Your New Play Set:

• It is recommended that on site adult supervision for children of all ages be
present while playground equipment is in use.

• Please restrict children from walking close to, in front of, behind or
between moving items.

• Restrict children from twisting swing chains or ropes since this may reduce
the strength of these items.

• Warn children to avoid swinging empty seats.

• Teach children to sit with their full weight on the center of the swing seat.

• Teach children to use the playground equipment in the intended manner.

• Teach children not to get off play equipment while still in motion.

• Parents should make sure children are dressed appropriately. For

example: wear well fitting clothing, shoes, avoid ponchos, and scarves or
any loose fitting clothing, which may be potentially hazardous while using
the playground equipment.

• Restrict children from climbing on playground equipment when wet.

• Check all nuts and bolts twice monthly during the usage season for

tightness. Tighten as required. It is particularly important to check &
tighten bolts at the beginning of each season.

• Check swings, chains, and slides for cracks or deterioration. Replacement
should be made at first sign of deterioration.

Playgrounds should be inspected on a regular basis. If any of the following conditions
are noted, they should be removed, corrected or repaired immediately to prevent
injuries: (see list, following page)

• Hardware that is loose, worn or that has protrusions or projections

• Exposed equipment footings

• Scattered debris, litter, rocks, or tree roots

• Rust and chipped paint on metal components

• Splinters, large crack, and decayed wood components.

• Deterioration and corrosion on structural components, which connect to the

ground

• Missing or damaged equipment components, such as handholds, guardrails,
swing seats

6

Play Set Surfacing Recommendations:

Below are some of the recommendations that the U.S. Consumer Product Safety

Commission (CPSC) offers from its

1. Protective Surfacing - Since almost 60% of all injuries are caused by falls to the ground,
protective surfacing under and around all playground equipment is the most critical safety
factor on playgrounds.

Certain manufactured synthetic surfaces also are acceptable; however, test data on shock
absorbing performance should be requested from the manufacturer.

Asphalt and concrete are unacceptable. They do not have any shock absorbing properties.
Similarly, grass and turf should not be used. Their ability to absorb shock during a fall can be
reduced considerably through wear and environmental conditions.

Certain loose-fill surfacing materials are acceptable. Surfacing materials are acceptable, such
as the types and depths shown in the table.

FALL HEIGHT IN FEET FROM WHICH A SERIOUS INJURY WOULD

NOT BE EXPECTED

Handbook for Public Playground Safety

.

Type of material 6" Depth 9" Depth 12" Depth

Double shredded bark mulch
Wood chips
Fine sand
Fine gravel

It should be recognized that all injuries due to falls cannot be prevented no matter what surfacing material is

6’ 10’ 11’
6’ 7’ 12’
5’ 5’ 9’
6’ 7’ 10’

used.

2. Fall Zones - A fall zone, covered with a protective surfacing material, is essential under
and around equipment where a child might fall. This area should be free of other equipment
and obstacles onto which a child might fall. Stationary climbing equipment and slides should
have a fall zone extending a Minimum of 6' in all directions from the perimeter of the
equipment.

Swings should have a fall zone extending a minimum of 6' from the outer edge of the support
structure on each side. The fall zone in front and back of the swing should extend out a
minimum distance of twice the height of the swing as measured from the ground to the top of
the swing support structure.

7

LEVELING YOUR FORT DURING ASSEMBLY

• Complete steps1-11 which will be the basic frame of the fort {i.e. four center posts with
base (sand box boards) and deck supports}

• Position in the most level area chosen for the play set, keeping in mind the location and
size of the swing beam, ladder, slides, etc. that extend off the fort.

• Once the frame is in the final position, check for vertical and horizontal levelness to
determine which side(s) will need to be dug into the ground to level the play set.

• With a shovel, score the ground around the outside edges of the sandbox boards on the
‘high’ side of the fort. This is the area that will be dug in. make sure to score deep
enough, the scored lines will be your digging template.

• Push the frame off and away from the scored area, far enough to dig and remove dirt
to reach the appropriate depth.

• Dig a channel along the scored line(s) for the base of the fort (corner post and sandbox
boards) to rest into. Dig the channel(s) to the same level depth. The bottom of the
channel(s) should be level to each other so your frame doesn’t teeter or rock because
the channel(s) are uneven.

• Once you have removed enough grass and dirt, slide/push the frame into the
channel(s). Place a level on the vertical and horizontal boards of the frame to determine
if enough soil, or too much, was removed.

• Repeat this process until the basic frame is plumb and level and in its final position
before completing the rest of the assembly.

Important: if you require a channel depth of more than 6”, then we recommend
you have your play set area professionally graded before completing assembly.

Example play area:

= AREA TO BE SCORED AND
CHANNELED FOR LEVELNESS

8

GORILLA CONGO CLIMBER II

KIT CONTENTS

COMPONENTS

Description Qty Check List

(Swings, Slides, Accessories)

Swingbelts w/ Chains 2 __________
Marine Grade Vinyl Tarp 1 __________
Rope Ladder (assembled) 1 __________
10ft. Wave Slide 1 __________
Climber Assembly Manual 1 __________
Rockwall Grips (assorted colors) 7 __________

Tire Swing w/ Swivel 1 ___________

Description

(Fort Hardware) see following pages

Description

(Wood Components) see following pages

REQUIRED TOOL LIST

Standard or Cordless Drill w/ Philips Bit (#2 square bit provided)
1/4” Drill Bit
3/8” Drill Bit
7/16” Drill Bit
1/2” Wrench or Socket
9/16” Wrench or Socket
Level
Tape Measure
Extension Cord (if using standard drill)
Hammer
Pencil

9

Please familiarize yourself with the manual, parts/components and general
construction process of your new playset before getting started.

SITE PLAN:

17.5’

20.5’

Playset height: 10 ½’

Approximate assembly time:

8 – 12 hours

{ 3 foot unobstructed safety perimeter around playset required, 6 foot
recommended }

10

General Info to Review before Installation

This page is a list of definitions and explanations used throughout our instructions to aid you
in the assembly of your playset.

Offset Holes- Throughout the installation procedure we will refer to parts with offset holes.
This refers to the orientation of the holes on board. An offset hole is one that is closer to one
side than it is to the other or in other words, it is not centered on the board. In the procedures
you will be instructed to attach the boards with the holes offset up or with the holes offset
down. This refers to which side of the board the hole/holes should be closer to. Offset holes
up= hole/holes will be closer to the top of the board. Offset holes down= hole/holes will be
closer to the bottom of the board. Note: Some parts do not have offset holes, but instead the
holes are on center. Therefore there will not be any reference to how to offset these parts.

Counter-sunk holes- Many of the parts that will be used have counter-sunk holes. A
counter-sunk hole is one that surrounds one side of a thru hole, but does not extend through
the wood it’s self. When using a counter-sunk hole the bolt will be inserted thro ugh the thru
hole and either the head of the bolt and washer or nut and washer will occupy the counter
sunk hole.

Lag Bolts- Lag bolts are used in the construction of our playsets to enhance the structural
integrity of the unit. There will not be predrilled holes in the post for lag bolt installation. Lag
bolts are self-tapping, though if you are using a manual socket wrench it may be necessary to
tap the head of the lag bolt with a hammer to actuate. You should also be sure to tighten the
lags completely. Power tools such as an impact wrench or power drill should have enough
torque to drive the lag bolts without using a hammer, but make sure not to over tighten as
this can cause the bolt threads to “strip out” in the post.

11

IMPORTANT INFORMATION:

IF YOU HAVE MISSING OR DAMAGED PARTS
OR NEED ASSISTANCE ASSEMBLING, PLEASE

CALL gorilla playsets MANUFACTURING
DIRECT.

[phone]

FACTORY HOURS – MON.–FRI., 9AM-6PM EST

DO NOT RETURN THIS PRODUCT TO THE RETAILER OR CONTACT
THE RETAILER DIRECT. THE RETAILER DOES NOT STOCK
COMPONENTS.

CONTACT INFO:
Gorilla Playsets, Inc.

190 Etowah Industrial Ct.
Canton, GA 30114
Tel. [phone]
Fax. [phone]
[e-mail]

12

3/8” x 9” CARRIAGE BOLT
QUANTITY: 1

3/8” x 6 1/2” CARRIAGE BOLT
QUANTITY: 17

3/8” x 4” CARRIAGE BOLT
QUANTITY: 2

3/8” x 3 1/2” CARRIAGE BOLT
QUANTITY: 2

13

5/16” x 3 1/2” HEX HEAD LAG BOLT
QUANTITY: 6

3/8” x 3 1/2” HEX HEAD LAG BOLT
QUANTITY: 22

5/16” x 1 1/2” HEX HEAD BOLT
QUANTITY: 16

5/16” x 2 1/2” HEX HEAD BOLT
QUANTITY: 4

5/16” x 4 1/2” HEX HEAD BOLT
QUANTITY: 32

5/16” x 3” EYE LAG BOLT
QUANTITY: 3

14

3/8” LOCK NUT
QUANTITY: 22

5/16” LONG BARREL T-NUT
QUANTITY: 52

#14 x 1 1/4” PAN HEAD SCREW
QUANTITY: 28

#8 x 1 1/4” WOOD SCREW---SLIDE
QUANTITY: 2

#8 x 2” WOOD SCREW-ROCK WALL, DECKS, PT, P SLAT
QUANTITY: 135

#8 x 2 1/2” WOOD SCREW-ROOF, WALLS
QUANTITY: 116

BOLT CAP
QUANTITY: 22

5/16” FLAT WASHER
QUANTITY: 58

3/8” FLAT WASHER
QUANTITY: 44

1/2” FLAT WASHER
QUANTITY: 22

15

16

16

17

18

19 20

21

Common installation practice

T

Installing T-nuts

When installing T-nuts into the wood, use a smooth faced hammer to
set the face of the T-nut flush into the wood.

Corner Post

-nut

Insert the barrel of the T-nut into the
predrilled hole. Using a smooth faced
hammer, drive the T-nut until the face
of the T-nut is flush to the wood.

This picture shows the T-nut insert and
installed flush to the wood.

Cross Section end views, you are looking at an X­ray view of the post and T-nut. The barrel of the
T-nut is in the corner post the line is the face of
the wood.

This picture shows an end view of the T-nut
insert and installed flush to the wood.
WARNING: DO NOT EMBED THE TOP OF THE
T-NUT INTO THE FACE OF THE WOOD

Flush
Correct

22