Sauder Carson Forge 418135 User manual

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sauder.com
Your center of
attention.
NOTE: THIS INSTRUCTION
BOOKLET CONTAINS IMPORTANT
SAFETY INFORMATION.
PLEASE READ AND KEEP FOR
FUTURE REFERENCE.
English pg 1-22
Français pg 23-25
Español pg 26-28
Lot # 364573 09/12/14
Purchased: __________________
Be sure to give us a ring before
making any returns. 1-800-523-3987
Media Console with Fireplace
Carson Forge Collection | 418135

Table of Contents Assembly Tools Required
Part Identification
Hardware Identification
Assembly Steps
Français
Español
Safety
Warranty
No. 2 Phillips Screwdriver
Tip Shown Actual Size
Hammer
Not actual size
Skip the power trip.
This time.
WARNING
!
3
4
5-22
23-25
26-28
29-30
31
95 lbs.
95 lbs.
17-3/8"
17-3/8"
59"
59"
418135 www.sauder.com/servicesPage 2
Use of a TV that is too heavy or large is hazardous. A TV that is too heavy will create a risk of a tip-over that can cause severe injury or
death. A TV that is too large for the available space might be accidentally pushed or bumped o the furniture, or subject to tip-over.
• Check the size and weight of your TV. Compare it to the diagram below – before you begin assembly!
• This Sauder unit is designed for use with televisions weighing less than 95 pounds. Never use with a TV that weighs more.
• The size of the television, front-to-back and side-to-side, must fit within the space defined in the diagram.
• Never place the front edge of the TV past the front edge of the TV support shelf (or stop molding – if equipped)
• Never allow the sides of the TV to extend past the side edges of the TV support surface.
• If the TV has a CRT picture tube, the picture tube cone may extend past the rear of the support shelf.
• Be sure to apply the warning label as instructed in the last assembly step. The label provides important safety related information.
• Read all FIREPLACE insert instructions prior to installing and removing it from your console.
Short Screwdriver

Part Identification
åWhile 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.
Now you know
our ABCs.
A RIGHT END (1)
B LEFT END (1)
C RIGHT UPRIGHT (1)
D LEFT UPRIGHT (1)
E SMALL UPRIGHT (1)
F TOP (1)
G BOTTOM (1)
H SHELF (1)
I HEARTH (1)
J LARGE BACK (1)
K SMALL BACK (2)
L DOOR (2)
M ADJUSTABLE SHELF (2)
N PANEL (2)
O SPACER (1)
P SKIRT BRACE (2)
Q LONG BRACE (1)
R SHORT BRACE (1)
S SKIRT (1)
T BOWED SKIRT (1)
U LEFT FRONT BASE (1)
V RIGHT FRONT BASE (1)
W SIDE BASE (2)
X TOP FRONT MOLDING (1)
Y TOP LEFT MOLDING (1)
Z TOP RIGHT MOLDING (1)
AA SHELF MOLDING (1)
BB UPRIGHT MOLDING (1)
69M FIREPLACE INSERT (1)
A
B
C
D
E
F
G
H
I
J
K
K
L
L
M
M
N
N
O
P
P
QR
S
T
U
V
W
W
X
Y
Z
AA
BB
69M
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Hardware Identification
åScrews are shown actual size. You may receive extra hardware with your unit.
FELT DISC CARD - 1
1M
METAL BRACKET - 8
4G SMALL METAL
BRACKET - 2
17G
BLACK 9/16" LARGE HEAD SCREW - 50
1S
SILVER 1-1/4" PAN HEAD SCREW - 4
45S
SUPPORT PIN - 4
4R
BLACK 1-7/8" FLAT HEAD SCREW - 14
2S
BLACK 2-1/4" FLAT HEAD SCREW - 17
26S
CAM COVER - 4
12P METAL PIN - 12 1R
19G LARGE METAL
BRACKET - 6
BLACK 1/2" FLAT HEAD SCREW - 8
11S
CAM SCREW - 19
8F
13H HINGE - 4
NAIL - 58
1N
HIDDEN CAM - 19
1F
RUBBER SLEEVE - 8
2R
(Refer to step 22 for proper location and application)
WARNING LABEL - 1
3L
WARNING
Never use this furniture with a TV that is too
large or too heavy. Severe injury or death
can occur.The TV and furniture will be
unstable and may tip.
-The TV must less than 95 lbs.
-The base of the TV must be able to sit
completely on this shelf.
-Refer to instruction book for complete
safety information.
Note: This is a permanent label. Do not try
to remove. Surface will be damaged.
02/ 02 269227
3M ANTI-SKID PAD - 1
418135 www.sauder.com/servicesPage 4
31G CORNER
BRACKET - 4
SILVER 1" LARGE HEAD SCREW - 4
102S

Step 1 Look for this icon. It means a
video assembly tip is available at
www.sauder.com/services/tips
å Assemble your unit on a carpeted floor or on the empty
carton to avoid scratching your unit or the floor.
å Push nineteen HIDDEN CAMS (1F) into the ENDS (A and B)
UPRIGHTS (C and D), SMALL UPRIGHT (E), SHELF (H), and
LONG BRACE (Q).
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Arrow
Arrow
1F
1F
Arrow
Arrow
1F The arrow in the HIDDEN
CAM must point toward the
hole in the edge of the board.
Hole
A
B
C
D
E
H
O

å Fasten eight METAL BRACKETS (4G) to the ENDS (A and B),
SMALL UPRIGHT (E), BOTTOM (G), and LONG BRACE (Q).
Use eight BLACK 9/16" LARGE HEAD SCREWS (1S).
å NOTE: Be sure the BRACKETS are even with the edges of
the ENDS, SMALL UPRIGHT, BOTTOM, and LONG BRACE.
Step 2
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BLACK 9/16" LARGE HEAD SCREW
(8 used in this step)
1S
4G
4G
4G
4G
4G
A
B
E
G
Q
Just think. The sooner
you do this, the sooner
you do something else.

å Turn nineteen CAM SCREWS (8F) into the TOP (F),
SHELF MOLDING (AA), and UPRIGHT MOLDING (BB).
å Fasten the TOP (F) to the ENDS (A and B).
Step 3
8F
8F
(19 total used)
(14 used in the TOP)
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AA
BB
F
F
The METAL BRACKET
should be here.
The METAL BRACKET
should be here.
A
B
Finished edge
Finished edge
Finished edge
1
2
Surface with HIDDEN CAMS
Surface without HIDDEN CAMS

å Fasten the TOP LEFT MOLDING (Y) to the LEFT END (B)
and the TOP RIGHT MOLDING (Z) to the RIGHT END (A).
Use four SILVER 1" LARGE HEAD SCREWS (102S). Do not
tighten these screws until step 7.
å Fasten the SMALL UPRIGHT (E) to the TOP (F). Tighten
two HIDDEN CAMS.
Step 4
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1
2
Angled edge
Angled edge
Y
Z
E
Surface with
HIDDEN CAMS
F
A
B
102S
SILVER 1" LARGE HEAD SCREW
(4 used in this step)

å Fasten the SPACER (O) to the TOP (F). Tighten four
HIDDEN CAMS.
å Fasten the SPACER (O) to the ENDS (A and B) and
SMALL UPRIGHT (E). Use three BLACK 9/16" LARGE
HEAD SCREWS (1S).
å Fasten the UPRIGHT MOLDING (BB) to the SMALL
UPRIGHT (E). Tighten two HIDDEN CAMS.
Step 5
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1
2
Surface without
HIDDEN CAMS
F
O
A
B
BLACK 9/16" LARGE HEAD SCREW
(3 used for the METAL BRACKETS)
1S
E
BB

å Fasten the TOP FRONT MOLDING (X) to the SPACER (O).
Use four SILVER 1-1/4" PAN HEAD SCREWS (45S).
å With a hammer, tap four SUPPORT PINS (4R) into the
UPRIGHTS (C and D) as shown to the right.
å Fasten the UPRIGHTS (C and D) to the TOP (F).
Tighten four HIDDEN CAMS.
Step 6
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C
C
D
D
Finished edge
Finished edge
1
2
4R
F
Finished surface
X
O
Surface with HIDDEN CAMS
Surface without HIDDEN CAMS
SILVER 1-1/4" PAN HEAD SCREW
(4 used for the MOLDING)
45S

å NOTE: You may need to use a short screwdriver in this step.
å Fasten the SHELF (H) to the UPRIGHTS (C and D) and
SMALL UPRIGHT (E). Use six BLACK 1-7/8" FLAT HEAD
SCREWS (2S).
å Fasten the BOTTOM (G) to the UPRIGHTS (C and D). Use
four BLACK 1-7/8" FLAT HEAD SCREWS (2S).
å With your hand, pull the MOLDINGS (X, Y, and Z) together
at the corners as you tighten the SILVER 1" LARGE HEAD
SCREWS from step 4.
Step 7
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BLACK 1-7/8" FLAT HEAD SCREW
(10 used in this step)
2S
1
2
C
D
E
H
G
Unfinished surface
X
The METAL
BRACKETS
should be here.
Y
Z
Tighten the screws from
step 4, while you pull
MOLDINGS (X and Z)
together at the corners.
Tighten the screws from
step 4, while you pull
MOLDINGS (Y and Z)
together at the corners.

å Fasten the SHELF MOLDNG (AA) to the SHELF (H).
Tighten three HIDDEN CAMS.
å Insert four METAL PINS (1R) into the SHELF (H).
å Fasten the PANELS (N) to the SHELF (H) by pushing them
over the METAL PINS (1R).
å Fasten the SKIRT (S) to the BOTTOM (G). Use two BLACK
9/16" LARGE HEAD SCREWS (1S).
Step 8
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1R
N
N
H
S
G
Groove
Groove
BLACK 9/16" LARGE HEAD SCREW
(2 used in this step)
1S
AA
1
2
These edges must be even.

å Fasten the SKIRT BRACES (P) to the SHORT BRACE (R).
Use two BLACK 1-7/8" FLAT HEAD SCREWS (2S).
å Fasten the HEARTH (I) to the BRACES (P and R) Use five
BLACK 2-1/4" FLAT HEAD SCREWS (26S).
Step 9
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BLACK 1-7/8" FLAT HEAD SCREW
(2 used in this step)
2S
These holes must be here.
I
P
P
P
P
R
R
BLACK 2-1/4" FLAT HEAD SCREW
(5 used in this step)
26S
Curved edge

å Fasten the HEARTH (I) to the ENDS (A and B),
UPRIGHTS (C and D), and PANELS (N). Use twelve
BLACK 2-1/4" FLAT HEAD SCREWS (26S).
Step 10
418135 www.sauder.com/servicesPage 14
BLACK 2-1/4" FLAT HEAD SCREW
(12 used in this step)
26S
A
B
C
D
N
N
I

å Carefully stand your unit on its TOP.
å Fasten the LONG BRACE (Q) to the SKIRT BRACES (P).
Use two BLACK 1-7/8" FLAT HEAD SCREWS (2S).
å Fasten the LONG BRACE (Q) to the HEARTH (I). Use
three BLACK 9/16" LARGE HEAD SCREWS (1S).
å Fasten the CORNER BRACES (31G) to the HEARTH (I)
and LONG BRACE (Q). Use twelve BLACK 9/16" LARGE
HEAD SCREWS (1S).
Step 11
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31G
31G
BLACK 1-7/8" FLAT HEAD SCREW
(2 used in this step)
2S
Q
P
P
BLACK 9/16" LARGE HEAD SCREW
(15 used in this step)
1S
I

å Fasten five LARGE METAL BRACKETS (19G) to the
HEARTH (I). Use five BLACK 9/16" LARGE HEAD
SCREWS (1S).
å Fasten the BASES (U, V, and W) to the CORNER
BRACKETS (31G). Use twelve BLACK 9/16" LARGE HEAD
SCREWS (1S).
å Fasten the FRONT BASES (U and V) to the LARGE
METAL BRACKETS (19G). Use two BLACK 9/16" LARGE
HEAD SCREWS (1S).
Step 12
418135 www.sauder.com/servicesPage 16
19G
BLACK 9/16" LARGE HEAD SCREW
(19 used in this step)
1S
These edges
must be even.
These edges
must be even.
Groove
Groove
W
W
V
U
I
31G
31G
31G
31G

å Carefully turn your unit over onto its front edges. Lay the SMALL BACKS (K)
over the two outer openings of your unit.
å Make equal margins along all four edges of the SMALL BACK (K). Push on
opposite corners of your unit if needed to make it "square".
å Fasten the SMALL BACKS (K) to your unit using thirty-four NAILS (1N).
å Lay the LARGE BACK (J) over the center opening of your unit. Fasten the
LARGE BACK to your unit using the remaining NAILS (1N).
å NOTE: The LARGE BACK will over lap the SMALL BACKS.
å NOTE: Perforations have been provided for access through the BACKS.
å Slightly bend the BOWED SKIRT (T) and slide it in the grooves of the
FRONT BASES (U and V).
Step 13
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Side Step: Make
nachos. (Optional, but
recommended.)
Do not stand the unit upright without the
BACK fastened. The unit may collapse.
Caution
Unfinished surface
NAIL
(58 used in this step)
1N
Bend the BOWED SKIRT (T)
and slide it into the grooves
of the SKIRTS (U and V).
U
V
T
T
J
K
K
NOTE: The BOWED SKIRT is not attached
so be sure it does not fall out when
standing your unit upright in Step 15.

Step 14
418135 www.sauder.com/servicesPage 18
å Fasten four HINGES (13H) to the DOOR (L). Use eight
BLACK 1/2" FLAT HEAD SCREWS (11S).
BLACK 1/2” FLAT HEAD SCREW
(8 used in this step)
11S
13H
13H
L
L

Step 15
418135www.sauder.com/services Page 19
å Carefully stand your unit upright.
å Before fastening the DOOR to your unit, be sure the
mounting screw is against the stops as shown in the right
diagram. If it isn't, loosen the mounting screw to slide it
against the stops. Then tighten the mounting screw.
å Fasten a DOOR (L) to the LEFT END (B) as shown in
the lower diagram. Use the screws in the HINGES. You
should start each SCREW a few turns before completely
tightening any of them.
å Peel a felt disc from the FELT DISC CARD (1M) and stick
them on each corner of the DOOR (L).
å Repeat this step for the other DOOR (L).
å See the next step for DOOR adjustments.
Mounting
screw
Stop
Hinge
1M
L
B
NOTE: The BOWED SKIRT is not
attached so be sure it does not fall
out when standing your unit upright.

Step 16
418135 www.sauder.com/servicesPage 20
Almost time to
celebrate! With a nap.
å Refer to the enlarged diagram to identify the parts on
the HINGES.
å The DOORS may need some adjustments. Follow the text
below to make needed adjustments.
å DOOR ADJUSTMENTS:
To adjust the DOORS from side to side (horizontal), loosen the
mounting screw several turns, then turn the adjusting screw in
or out. Tighten the mounting screw after making adjustments.
å To adjust the DOORS up and down (vertical), loosen both vertical
adjustment screws. Move the DOORS up or down to the desired
location. Tighten the screws after making adjustments.
å To adjust the DOORS in or out (depth), loosen the
mounting screw one turn and move the DOORS in or
out, as needed. Tighten the mounting screw after making
adjustments.
Adjusting screw (horizontal) Mounting screw (depth)
(vertical adjustment)