Sauder Carson Forge 415117 User manual

PLEASE CONTACT US
BEFORE RETURNING
YOUR UNIT TO THE STORE
1-800-523-3987
www.sauder.com
Made in the USA
Archbold, OH
NOTE: THIS INSTRUCTION BOOKLET CONTAINS
IMPORTANT SAFETY INFORMATION.
PLEASE READ AND KEEP FOR FUTURE REFERENCE.
Lot #: 355966 10 / 11 / 13
Date Purchased: ____________________
English.................... Page 1-22
Français...............Pages 23-25
Espanol.............Páginas 26-28
415117
4-Drawer Chest
Carson Forge Collection

ASSEMBLY TOOLS REQUIRED
Hammer
No. 2 Phillips Screwdriver
Tip Shown Actual Size
ADULT ASSEMBLY REQUIRED
PART IDENTIFICATION: While not all parts are labeled, some of the parts will have a label or an inked
letter on the edge to help distinguish similar parts from each other. Use this PART IDENTIFICATION to help
identify similar parts.
TABLE OF CONTENTS
Part Identification.......................3
Hardware Identification .............4
Assembly Steps....................5-22
Français..............................23-25
Espanol...............................26-28
Safety .................................29-30
Warranty...................................31
A RIGHT END 1
B LEFT END 1
C TOP 1
D BOTTOM 1
E DUST RAIL 1
F DRAWER BRACE 4
G RIGHT FRONT LEG 1
H LEFT FRONT LEG 1
I REAR LEG 2
J LARGE DRAWER FRONT 3
K DRAWER FRONT 1
L BOTTOM MOLDING 1
M END MOLDING 2
N BACK 1
D12 RIGHT DRAWER SIDE 1
D13 LEFT DRAWER SIDE 1
D30 LARGE RIGHT DRAWER SIDE 3
D31 LARGE LEFT DRAWER SIDE 3
D60 DRAWER BACK 1
D171 LARGE DRAWER BACK 3
D945 DRAWER BOTTOM 4
Page 2 www.sauder.com/services 415117
A
B
C
D
E G
H
I
I
L
M
N
M

Page 3
www.sauder.com/services415117
FF
J
K
D12 D30
D60
D31
D13
D945
D171
D945
PART IDENTIFICATION
40CB CABINET LEFT - 4 40CA CABINET RIGHT - 4 40CC DRAWER RIGHT - 4
40CD DRAWER LEFT - 4 SLIDE CAM - 8
10A 8E CORNER ACCENT - 2
FOOT - 4
10E TACK GLIDE - 4 12E HIDDEN CAM - 18 1F
CAM DOWEL - 12
2F CAM SCREW - 6 8F SAFETY BRACKET - 1 1G
HARDWARE IDENTIFICATION

HARDWARE IDENTIFICATION
Screws are shown actual size. You may receive extra hardware with your unit.
Page 4 www.sauder.com/services 415117
5L WARNING LABEL - 1
(Refer to step 17 for proper
location and application)
WARNING
!
Serious or fatal crushing injuries can
occur from furniture tip-over. To help
prevent tip-over:
• Place heaviest items in the lowest drawers.
• Unless specifically designed to accommodate, do not
set TVs or other heavy objects on top of this product.
• Never allow children to climb or hang on drawers,
doors, or shelves.
• Never open more than one drawer at a time.
• If equipped with a drawer interlock system, do not
defeat or remove it.
Use of tip-over restraints may only reduce,
but not eliminate, the risk of tip-over.
This is a permanent label. Do not attempt to remove!
04/10 332296
PULL - 3
53K
GOLD 5/16" FLAT HEAD SCREW - 32
3S
BLACK 1-9/16" FLAT HEAD SCREW - 20
30S
METAL PIN - 4
1R
BLACK 9/16" FLAT HEAD SCREW - 4
32S
KNOB - 2
52K
GOLD 1" MACHINE SCREW - 2
50S
SILVER 1/2" MACHINE SCREW - 6
38S
BLACK 2-1/4" FLAT HEAD SCREW - 6
26S
BLACK 1-7/8" PAN HEAD SCREW - 1
16S
BLACK 9/16" LARGE HEAD SCREW - 1
1S
SILVER 5/8" MACHINE SCREW - 2
15S
NAIL - 40
1N
20G DRAWER STOP - 4 29G SAFETY STOP - 4
INTERLOCK
TRACK - 1
21G

Look for this icon. It means a video
assembly tip is available at:
www.sauder.com/services/tips
1
1
S
t
e
p
Page 5
www.sauder.com/services415117
Assemble your unit on a carpeted floor or on the empty carton to avoid scratching your unit or the floor.
Push eighteen HIDDEN CAMS (1F) into the ENDS (A and B), BOTTOM (D), and DRAWER BRACES (F). Then, insert the metal
end of a CAM DOWEL (2F) into each HIDDEN CAM, except the long edges of the ENDS (A and B).
Do not tighten the HIDDEN CAMS in this step.
Arrow
1F
Arrow
1F
Arrow
(12 used)
(18 used) 1F
2F
Insert the metal end of the CAM
DOWEL into the HIDDEN CAM.
Arrow
A
B
D
FF
F
F
Arrow
1F
2F
Do not insert CAM DOWELS into these edges.

2
2
S
t
e
p
Page 6 www.sauder.com/services 415117
Turn six CAM SCREWS (8F) into the FRONT LEGS (G and H).
Fasten two CORNER ACCENTS (8E) to the FRONT LEGS (G and H). Use two SILVER 5/8" MACHINE SCREWS (15S).
8F
(6 used)
SILVER 5/8" MACHINE SCREW
(2 used in this step)
15S
G
H
8E
8E
Angled edge

3
3
S
t
e
p
Page 7
www.sauder.com/services415117
A
B
Fasten the REAR LEGS (I) to the ENDS (A and B). Use six BLACK 2-1/4" FLAT HEAD SCREWS (26S).
Turn four BLACK 9/16" FLAT HEAD SCREWS (32S) into the ENDS (A and B) until the shoulder of the SCREWS rests on the
surface of the ENDS.
Slide the MOLDINGS (M) onto the ENDS (A and B). Line up the groove in the MOLDINGS over the head of the SCREWS
in the ENDS.
BLACK 2 1/4" FLAT HEAD SCREW
(6 used for the REAR LEGS)
26S
Surface without
HIDDEN CAMS
Surface without
HIDDEN CAMS
Edge with
HIDDEN CAMS
Edge with
HIDDEN CAMS Angled edge
These edges
should be even.
Apply pressure with your hands as
you guide the MOLDINGS over
the SCREWS and onto the ENDS.
Shoulder
These edges
should be even.
BLACK 9/16" FLAT HEAD SCREW
(4 used in this step)
32S
M
M
I
I
Bottom edges
should be even.

4
4
S
t
e
p
Page 8 www.sauder.com/services 415117
G
H
A
B
Surface
with
HIDDEN
CAMS
Surface
with
HIDDEN
CAMS
This pin must insert into the location
holes in the RIGHT END (A).
Fasten the FRONT LEGS (G and H) to the ENDS (Aand B). Tighten six HIDDEN CAMS.
Insert four SAFETY STOPS (29G) into the holes shown in the RIGHT END (A).
29G
These edges
should be even.
29G
Angled edge
Angled edge

5
5
S
t
e
p
Page 9
www.sauder.com/services415117
Diagram 1. Measure 2 -1/2" from one end of the INTERLOCK TRACK (21G). Position the INTERLOCK TRACK as shown.
ACTUATOR / TRACK ATTACHMENT:
Diagram 2. Tilt the first edge of the INTERLOCK TRACK (21G) into the CABINETACTUATOR (29G).
Diagram 3. Rotate the INTERLOCK TRACK and apply force to snap the second edge into the CABINETACTUATOR.
Diagram 4. Repeat the ACTUATOR / TRACK ATTACHMENT for the next CABINETACTUATOR while holding the previously
completed CABINETACTUATOR in its location hole. Repeat these steps until all ACTUATORS have been attached. Visually check
that all INTERLOCK TRACK edges have been snapped into the CABINETACTUATORS as shown in diagram 3.
Diagram 5. Remove the INTERLOCK TRACK assembly from Diagram 4 and flip it over before inserting the INTERLOCK TRACK
(21G) with CABINETACTUATORS (29G) into the groove in the RIGHT END (A).
4.
1.
2. 3.
21G
29G
A
Be sure the
interlock track
snaps into each
cabinet actuator.
The interlock system is a safety feature that prevents more than one drawer from opening at the
same time. Do not use excessive force to open the drawers.
5.
A
21G
29G
21G
Surface
with
HIDDEN
CAMS
Surface
with
HIDDEN
CAMS
2-1/2"
29G

6
6
S
t
e
p
Page 10 www.sauder.com/services 415117
A
B
Fasten four CABINET RIGHTS (40CA) and four CABINET LEFTS (40CB) to the ENDS (A and B). Use sixteen GOLD 5/16" FLAT
HEAD SCREWS (3S) through holes #1 and #3.
GOLD 5/16” FLAT HEAD SCREW
(16 used in this step)
3S
1
2
3
32
1
Roller end
1
2
3
1
2
3
1
2
3
32
1
32
1
32
1
Roller end
H
G
4
4
4
4
4
4
4
4
After fastening the CABINET RIGHTS to the INNER RIGHT
END (B), the SAFETY STOP should touch the top edge of the
RAILS. If the gap is larger than 1/16”, the drawers could lock
up and not open. If this happens, open two drawers at the same
time to override the interlock system. Remove the drawers to
re-adjust the INTERLOCK TRACK assembly.
29G
40CA

7
7
S
t
e
p
Page 11
www.sauder.com/services415117
B
C
Surface with holes
Rounded edge
Caution
Risk of damage or
injury. Hidden Cams
must be completely
tightened. Hidden
Cams that are not
completely tightened
may loosen, and parts
may separate.
To completely tighten:
Start Tighten
Arrow
Arrow
Maximum
210 degrees
Minimum
190 degrees
Fasten the LEFT END (B) to the TOP (C). Tighten two HIDDEN CAMS.
Surface
with
HIDDEN
CAMS
Do not stand the unit upright without the
BACK fastened. The unit may collapse.
Caution
H

8
8
S
t
e
p
Page 12 www.sauder.com/services 415117
Fasten the BOTTOM (D) to the LEFT END (B). Tighten two HIDDEN CAMS.
Slide the BOTTOM MOLDING (L) onto the notched edge of the BOTTOM (D).
*U.S. Patent No. 5,499,886
D
B
Surface with
HIDDEN CAMS
L
Notched edge
Maximum
210 degrees
Minimum
190 degrees
Arrow

9
9
S
t
e
p
Page 13
www.sauder.com/services415117
A
D
C
E
Surface without
HIDDEN CAMS
Insert four METAL PINS (1R) into the DUST RAIL (E).
Insert the METAL PINS (1R) in one end of the DUST RAIL (E) into the holes in the LEFT END (B).
Fasten the RIGHT END (A) to the TOP (C) and BOTTOM (D). Tighten four HIDDEN CAMS.
NOTE: Be sure the METAL PINS (1R) in the end of the DUST RAIL (E) insert into the holes in the RIGHT END (A).
NOTE: You may need help in this step.
B
1R
(4 used)
Rounded edge
Maximum
210 degrees
Minimum
190 degrees
Arrow
G

10
10
S
t
e
p
Page 14 www.sauder.com/services 415117
Carefully turn your unit over onto its front edges. Unfold the BACK (N) and lay it over your unit.
Make equal margins along all four edges of the BACK (N). Push on opposite corners of your unit if needed to make it “square”.
Fasten the BACK (N) to your unit using the NAILS (1N).
Do not stand the unit upright without the
BACK fastened. The unit may collapse.
Caution
NAIL
(40 used in this step)
1N
Unfinished
surface
N
These holes should
be here over the
screw head.

11
11
S
t
e
p
Page 15
www.sauder.com/services415117
Push four FEET (10E) onto the LEGS (G, H, and I).
With a hammer, gently tap four TACK GLIDES (12E) through the holes of the FEET (10E).
10E
10E
12E H
I
G
I
10E
10E

12
12
S
t
e
p
Page 16 www.sauder.com/services 415117
Insert the LARGE DRAWER SIDES (D30 and D31) at an angle
into the slot at each end of the LARGE DRAWER FRONT (J).
Slide the DRAWER BOTTOM (D945) into the grooves in
the LARGE DRAWER SIDES (D30 and D31) and LARGE
DRAWER FRONT (J).
Groove
The tabs should insert freely into the slots.
Gently tilt the DRAWER SIDES side to
side until the tabs slip into the slots.
UNFINISHED
Surface with
HIDDEN CAM
VIEW THE T-LOCK BOX VIDEO
12
34
Be sure the DRAWER
BOTTOM inserts into the
DRAWER FRONT groove.
Fasten the DRAWER BRACE (F) to the LARGE DRAWER
FRONT (J). Tighten one HIDDEN CAM.
Fasten the LARGE DRAWER BACK (D171) to the LARGE
DRAWER SIDES (D30 and D31) and DRAWER BRACE (F).
Use five BLACK 1-9/16" FLAT HEAD SCREWS. Repeat this
step for the remaining drawers.
Start each screw a few turns before
completely tightening any of them.
BLACK 1-9/16" FLAT HEAD SCREW
(20 used in this step)
30S
With the palm of your hand, tap the
DRAWER BOTTOM down into the groove.
Maximum
210 degrees
Minimum
190 degrees
Arrow
F
J
D30
D31
D945
D171
J
J
D30
D31
D30
D31
F

13
13
S
t
e
p
Page 17
www.sauder.com/services415117
D31
12
3
Roller end
GOLD 5/16" FLAT HEAD SCREW
(8 used in this step)
3S
Screw head - turn CAM to line up holes in
SLIDES with holes in DRAWER SIDES.
Insert a SLIDE CAM (10A) into the LARGE LEFT DRAWER SIDE (D31).
Fasten a DRAWER LEFT (40CD) to the LARGE LEFT DRAWER SIDE (D31). Use two GOLD 5/16" FLAT HEAD SCREWS (3S)
through holes #2 and #4.
NOTE: The screw head in the CAM must be visible through the slotted hole in the SLIDE.
10A (4 used)
4

14
14
S
t
e
p
Page 18 www.sauder.com/services 415117
Insert a SLIDE CAM (10A) into the LARGE RIGHT DRAWER SIDE (D30).
Diagram 1. Insert the tabs on a DRAWER STOP (20G) into the slots in a DRAWER RIGHT (40CC). You may need to insert one tab
first, then the other.
Diagram 2. Visually check that the DRAWER STOP (20G) is seated in the DRAWER RIGHT (40CC).
Diagram 3. If the DRAWER STOP is not seated, use your hammer to gently tap the DRAWER RIGHT until the tabs are properly
seated in the slots.
Now, fasten this DRAWER RIGHT (40CC) to the LARGE RIGHT DRAWER SIDE (D30). Use two GOLD 5/16” FLAT HEAD
SCREWS (3S) through holes #2 and #4.
NOTE: The screw head in the CAM must be visible through the slotted hole in the SLIDE.
Repeat steps 13 and 14 for the other drawers.
D30
3.
These tabs must insert into the slots.
Slot
2.
20G Seated
Post 20G
40CC 40CC
10A
Screw head - turn CAM to line
up the hole in the SLIDE with
hole in the DRAWER SIDE.
1
2
3
GOLD 5/16” FLAT HEAD SCREW
(8 used in this step)
3S
Roller end
20G
40CC
(4 used)
4

15
15
S
t
e
p
Page 19
www.sauder.com/services415117
Fasten two KNOBS (52K) to the DRAWER FRONT (K). Use two GOLD 1" MACHINE SCREWS (50S).
Fasten a PULL (53K) to the LARGE DRAWER FRONT (J). Use two SILVER 1/2" MACHINE SCREWS (38S).
Repeat this step for the remaining LARGE DRAWER FRONTS (J).
K
52K
J
53K
GOLD 1" MACHINE SCREW
(2 used for the KNOBS)
50S
SILVER 1/2" MACHINE SCREW
(6 used for the PULLS)
38S
52K

16
16
S
t
e
p
Page 20 www.sauder.com/services 415117
Carefully stand your unit upright.
We recommend using the SAFETY BRACKET (1G) for added stability. Use a BLACK 9/16" LARGE HEAD SCREW (1S) into the
top of the unit and a BLACK 1-7/8" PAN HEAD SCREW (16S) into a stud in your wall.
BLACK 9/16" LARGE HEAD SCREW
(1 used into the top of your unit)
1S
1G
16S
BLACK 1-7/8" PAN HEAD SCREW
(1 used into a stud in your wall)