SMP SPCAT, SPCAR, SPHIP, SPBIK, SPFIS Installation Instructions Manual

INSTALLATION INSTRUCTIONS

POLYNESIA SPRINGERS

SPCAT,SPBIK,SPCAR,SPHIP & SPFIS

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INTENTIONALLY LEFT BLANK

© SMP (PLAYGROUNDS) LTD, TEN ACRE LANE, THORPE, EGHAM, SURREY, TW20 8RJ POLYNESIA SPRINGERS

CONTENTS

1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

2 PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2

3 INSTALLATION & ASSY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

4 POST INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

Appendix A: SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

1 SPRING SUB-ASSEMBLY (CODE 86559999). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

2 SEAT & PROFILE SUB-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2

2.1 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2

2.2 PROFILE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2

Appendix B: SPCAR FOOTREST REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

1 FOOTREST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

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© SMP (PLAYGROUNDS) LTD, TEN ACRE LANE, THORPE, EGHAM, SURREY, TW20 8RJ POLYNESIA SPRINGERS

1 SPECIFICATIONS

REFERENCE SPCAT SPBIK

OVERALL HEIGHT (H) m 0.71/.61* 0.72/0.62* 0.73/0.63* 0.70/0.60* 0.71/0.61*

SEAT HEIGHT (h) m 0.50/0.40*

LENGTH (L) m 0.93 1.00 1.21 1.06 1.01

WIDTH (W) m 0.34

WEIGHT kg 36

HEAVIEST PART kg 23

LARGEST PART L x W x H m 0.60 x 0.60 x 0.50

CONCRETE m

MINIMUM SPACE L x W x H m 3.40 x 2.75 x 3.00

MAXIMUM FREEFALL HEIGHT m 0.50 / 0.40*

FALLING SPACE AREA m

IMPACT AREA (WET POUR) m

RUBBER TILES 1m x 1m 5

LOOSE FILL AREA (SAND/BARK) m

MANHOURS hr 2

MANPOWER 2

CONSTRUCTIONAL SPACE m 3 x 3

3

2

2

2

SPCAR

(DISCONTINUED)

0.05/0.07 *

6

5

7

SPHIP SPFIS

* The second figure refers to loose-fill installations

*NOTE: All dimensions in metres.

Concrete mix is recommended at:

1 part cement;

2 parts sand;

4 parts aggregate;

by volume with 20mm aggregate

(20 N/mm

2

min compressive strength )

The freefall height of the springers is less than 0.6m and therefore in accordance with EN1176 it does not strictly
require impact absorbing surfacing which has been fully tested to EN1177. However, if they are being installed on
hard surfaces such as concrete or tarmac, we recommend that a minimum surfacing area as indicated in the chart
above is specified to enhance the safety of its provision. If they are being provided on a grass surface, a suitable
level of maintenance will be required to ensure the impact attenuation properties are not significantly reduced.

NOTE: FIGS 1 & 2. Generally, it is recommended that loose fill surfaces are installed to a depth of 300mm. However

with certain loose fill materials, a greater depth may be required. This will need to be determined by allowing
100mm for dispersal in addition to the thickness required to achieve the required critical fall height.

Constructional Space (shown in the above table) is the approximate working area required to layout and assemble
the equipment.

For the safe operation of this equipment it must be installed on horizontal ground with the required minimum space.

Tools: Plumbline, 5m tape measure, Spirit level, Torque wrench, 5/16" Socket, 2-off 17mm AF Sockets & Drivers,

M10 Torx tool (Supplied with unit).

Minimum Personal Protective Equipment: Gloves, Armoured boots & Protective goggles.

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Section 1 Page 1

POLYNESIA SPRINGERS © SMP (PLAYGROUNDS) LTD, TEN ACRE LANE, THORPE, EGHAM, SURREY, TW20 8RJ

700

700

W

H

h

L

100

500

FINISHED
SURFACE
LEVEL

Fig 1 Standard Installation

1000

700

300*

100

300

FINISHED
SURFACE
LEVEL

Fig 2 Loose fill Installation

2 PARTS LIST

UN-ASSEMBLED COMPONENTS

ITEM CODE DESCRIPTION QTY.

1.1 SEE APPENDIX A PROFILE SUB-ASSY 1

1.2 86559999 SPRING SUB-ASSY 1

*1.3 86009002 BASE SUPPORTS 4

*1.4 86009001 BASE PLATE 2

1.5 10251125 BOLT-M10x125 LG 2

1.6 10291000 WASHER-PLAIN M10 12

1.7 10281000 LOCKNUT-M10 4

1.8 19028651 PLASTIC CAP - (FLAT STEPPED HEAD) 6

*1.9 10121030 RESISTORX HEAD M10x30 LG 8

1.10 10121020 RESISTORX HEAD M10x20 LG 2

1.11 86569003 OUTER POLY COVER 2

1.12 86569001 SEAT 1

1.13 86012001 HANDLE 4

1.14 86012002 HANDLE CAP- (DOMED HEAD) 4

1.15 86012005 LOCATOR 2

1.16 10121065 RESISTORX HEAD M10 X 65LG 4

- 10121000 M10 TORX TOOL 1

* THESE ITEMS ARE SUPPLIED IN PACKING BOX WITH SPRING SUB-ASSY (86559999).

Section 1 Page 2

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© SMP (PLAYGROUNDS) LTD, TEN ACRE LANE, THORPE, EGHAM, SURREY, TW20 8RJ POLYNESIA SPRINGERS

1.2

1.3

1.9

1.4

STANDARD INSTALLATION

LOOSE FILL INSTALLATION

Fig 3

1.6

1.9

Fig 4

PROFILE

1.2

FIG.5

1.6 1.7 1.8

1.1

1.8

1.6

1.11

1.5

1.6

1.81.71.6

1.10

1.12

3 INSTALLATION & ASSY PROCEDURES

PRE-INSTALLATION INSPECTION :

Inspect all parts for damage (that may have occurred during transportation &
storage). Finish Coatings, if found to be damaged these should be made good
before erection. Any damaged or missing parts must be replaced.

i) Warn the public of the risk of injury, by placing signs and fencing the

surrounding area, before commencing installation.

ii) Note if the installation is 'standard' or 'loose fill',then assemble the base

supports (1.3) to the base plates (1.4) the appropriate way round using 4­off Torx bolts (1.9) and fully secure.(Fig 3).

iii) Align the base sub-assy onto the spring sub-assy (1.2) in the angular

position shown in Fig 4.

iv) Assemble the spring sub-assy onto the base sub-assy using 4-off Torx

bolts (1.9) and washers (1.6).Tighten Torx bolts to a torque setting
between 40-43 Nm (30-32 lbf ft). (Fig 4).

v) Position the unit, mark out the foundation holes (Figs 1 & 2). Place the

unit to one side and excavate the holes. If applicable refer to the site
plan for unit location.

vi) Place the unit into the hole, then level and square the unit. Pour

concrete into the hole to a minimum thickness of 100mm (Figs 1 & 2).
Allow to cure before continuing (Recommended initial curing time is 48
hours minimum).

vii) Backfill the hole with earth to the required level, taking into

account any 'impact absorbing surfacing requirements'
(Figs 1 & 2). Refer to separate instructions if applicable.

viii) Place body sub-assy (1.1) onto spring & base sub-assy.

Align holes. Place bolt (1.5) thro' plain washer (1.6) and
outer poly cover with c'bore facing outermost (1.11) & feed
thro' spring sub assy & body sub assy. Fit washer (1.6) &
nut (1.7).Tighten bolts to a torque setting between 24-27
Nm (18-20 lbf ft).(Fig 5).

ix) Place the seat (1.12) into position, tucking front of seat into

slot on profile. From underside, place bolt (1.10) thro' plain
washer (1.6) & feed thro' holes in spring sub-assy & seat holes.
Fit washer (1.6) and nut (1.7).Tighten bolts to a torque setting
between 24-27 Nm (18-20 lbf ft).(Fig 6).

x) Tap plastic cap (1.8) into recess on both sides of body & seat top

face, ensuring they finish flush with the surrounding plastic
surface with no sharp edges.

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FIG.6

Section 1 Page 3

POLYNESIA SPRINGERS © SMP (PLAYGROUNDS) LTD, TEN ACRE LANE, THORPE, EGHAM, SURREY, TW20 8RJ

1.61.13

1.14

1.16

1.15

1.1

xi) Place locators (item 1.15) into the rectangular holes in front

profile of the profile assembly (item 1.1). (FIG.6A).

xii) Slide handles (item 1.13) onto locators (item 1.15) and

secure with M10 x 65 resistorx bolts (item 1.16) and M10
washers (item 1.6). Tighten to a torque setting of 24-27 Nm
(18-20 lbf ft). (FIG.6A).

xiii) Position handle caps (item 1.14) in end of handles and tap

into position, ensuring they finish flush with the surrounding
plastic surface with no sharp edges.

FIG.6A

4 POST INSTALLATION INSPECTION

CHECK CHECK

1 The unit is installed at the correct seat height.

2 All fixings are tightened to the correct torque and have no protruding sharp edges.

3 Paint work is not damaged.

4 The polyethylene is not damaged.

5 Concrete foundations are secure.

6 Concrete has a water shed away from legs.

7 Adequate provision of impact absorbing surfacing and no obstructions or trip points within

the equipments falling space.

8 Site is clear of all tools and rubbish.

9 Remove any warning signs.

3

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
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Section 1 Page 4

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© SMP (PLAYGROUNDS) LTD, TEN ACRE LANE, THORPE, EGHAM, SURREY, TW20 8RJ POLYNESIA SPRINGERS

Fig 7

2.8

2.9

2.10

2.11

Fig 8

2.2

2.3

2.4

2.2

2.3

2.4

2.5

2.6

2.7

Fig 9

2.2

2.3

2.4

2.8

2.9

2.10

2.11

2.13

Appendix A: SUB-ASSEMBLIES

The assemblies described below are for the spring and profile sub-assemblies. These will be supplied complete by
SMP. Instructions are included should the units need to be dis-assembled.

1 SPRING SUB-ASSEMBLY (CODE 86559999)

PARTS LIST

SPRING SUB-ASSY

ITEM CODE DESCRIPTION QTY.

2.1 86009003 BASE PLATE 1

2.2

2.3 NYLOC NUT-M12 6

2.4 WASHER-PLAIN M12 6

2.5

2.6 NYLOC NUT-M12 2

2.7 WASHER-PLAIN M12 2

2.8

2.9 NYLOC NUT-M12 4

2.10 WASHER-PLAIN M12 4

2.11 86009007 CLAMPING BLOCK 2

2.12 86009005 SPRING 1

2.13 86559004 TOP MOUNTING 1

86009006A

86009006B

86009006C

U-BOLT 43mm LONG 3

U-BOLT 55mm LONG 1

U-BOLT 69mm LONG 2

i) Place U-bolt (2.8) over the spring approximately one coil up from the base.

Locate the clamping block (2.11) over the threaded ends of the U-bolt,
ensuring that the taper and the curved face of the block are the correct way
round. "Wind" the bolt and clamping block down the spring until it is pinched
between the spring coils and over the holes in the base mounting. Place the
threads in the holes and secure in position with M12 nuts (2.9) and washers
(2.10). Do not tighten (Fig 7).

ii) Place U-bolt (2.5) over the first two coils and through the base mounting.

Place the remaining two U-bolts (2.2) over the first coil and through the
base mounting. Secure in position with M12 nuts (2.3) and washers (2.4).
(Fig 8).

iii) Place the top mounting bracket (2.13) onto the spring assy in the position

shown so that it is in line with the four fixing holes of the base plate (Figs 8
& 9).

iv) Place U-bolt (2.8) over the first two coils. Locate the clamping block (2.11)

over the threaded ends of the U-bolt, ensuring that the taper and the curved
face of the block are the correct way round, and through the top mounting
bracket (2.13). Place the remaining U-bolt (2.2) over the first coil and
through the top mounting bracket. Secure in position with M12 nuts (2.3)
and washers (2.4). Tighten the nuts evenly until the spring is fully secured
and in alignment with the base plate to a final torque setting between 34-38
Nm (25-27 lbf ft) (Fig 9).

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Appendix A Page 1

POLYNESIA SPRINGERS © SMP (PLAYGROUNDS) LTD, TEN ACRE LANE, THORPE, EGHAM, SURREY, TW20 8RJ

FIG.10

3.5 3.8 3.9

3.2

3.3

3.8

3.6

3.4

3.93.83.7

3.9

3.8

3.5

3.1

3.9

2 SEAT & PROFILE SUB-ASSEMBLY

2.1 PARTS LIST

SEAT & PROFILE SUB-ASSY

ITEM CODE DESCRIPTION QTY.

3.1 SEE BELOW FRONT PROFILE 1

3.2 SEE BELOW REAR PROFILE 1

3.3 SEE BELOW INNER BODY PROFILE 2

3.4 SEE BELOW SPACER 2

3.5 10281000 LOCKNUT-M10 4

3.6 10251044 BOLT-M10x45LG 2

3.7 10251080 BOLT-M10x80LG 2

3.8 10291000 WASHER-PLAIN-M10 8

3.9 19028651 PLASTIC CAP 8

2.2 PROFILE IDENTIFICATION

REFERENCE SPBIK

PROFILE DESCRIPTION BIKE CAR CAT FISH HIPPO

FRONT PROFILE (3.1) No. 86560011 86560021 86560031 86560051 86560061

REAR PROFILE (3.2) No. 86560012 86560022 86560032 86560052 86560062

INNER BODY PROFILE (3.3) No. 86560013 86560023 86569002 86569002 86569002

SPACER (3.4) No. 86569004 86560024 86569004 86569004 86569004

i) Position 85mm & 45mm long bolts (items 3.6 & 3.7) with plain washers (items 3.8), ensuring the counterbores

on items 3.4 and 3.3 face outermost. (FIG.10)

ii) Tighten to a torque setting between 24-27 Nm (18-20 lbf ft). Position plastic caps (item 3.9) over counterbores

and tap into place, ensuring they finish flush with the surrounding plastic surface with no sharp edges..

SPCAR

(DISCONTINUED)

SPCAT SPFIS SPHIP

Appendix A Page 2

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FIG.11

4.2

4.5

4.1 4.4

4.3

FRONT PROFILE

INNER BODY PROFILE

Appendix B: SPCAR FOOTREST REPLACEMENT

The assembly below is for the replacement of an existing cylindrical footrest with a new headed type footrest. The
parts list includes all the components required to complete the assembly.

1 FOOTREST ASSEMBLY

PARTS LIST

ITEM CODE DESCRIPTION QTY.

4.1 86012001 HANDLE 2

4.2 86012002 HANDLE CAP - (DOMED HEAD) 2

4.3 86012005 LOCATOR 1

4.4 10291000 WASHER-PLAIN M10 2

4.5 10251080 HEX HD. BOLT M10 X 80 2

4.6 19028651 PLASTIC CAP - (FLAT STEPPED HEAD) 12

i) Dismantle the SPCAR springer body. See Section 1-3 & Appendix A 2.2 Installation & Assy Procedures and

reverse the procedure.

ii) Remove Locator from rectangular hole in Front Profile and discard.

iii) Open out the counterbored hole in both Inner Body Profiles only by drilling through with a Ø20mm drill. (This

allows access to the Front Profile register slot for the Locator).

iv) Re-assemble springer body. See Section 1-3 & Appendix A 2.2 Installation & Assy Procedures.

v) Place Locator (Item 4.3) through hole in Inner Body Profiles and Front Profile. Slide handles (item 4.1) onto

locator (item 4.3) and secure with M10 x 80 Hex head bolts (item 4.5) and M10 washers (item 4.4). (Apply
Aradite or similar to bolt threads.) Tighten to a torque setting of 24-27 Nm (18-20 lbf ft). (FIG.11)

NOTE: When assembling the Hex head bolts, one bolt should be screwed in for 10 revolutions before

assembling the second bolt to the recommended torque settings. This ensures that the locator is
central about the front Profile thickness.

vi) Position handle caps (item 1.2) in end of handles and tap into position, ensuring they finish flush with the

surrounding plastic surface with no sharp edges..

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Appendix B Page 1

POLYNESIA SPRINGERS © SMP (PLAYGROUNDS) LTD, TEN ACRE LANE, THORPE, EGHAM, SURREY, TW20 8RJ

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Appendix B Page 2 ISSUE N