Whalen Furniture Mfg. Inc. Factory No. 4 Page # 1

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1 ADULT ASSEMBLY REQUIRED DUE TO THE PRESENCE OF SMALL PARTS, SHARP POINTS, SHARP EDGES If you have any questions regarding assembly or if you are missing parts, do not return this item to Sam s Wholesale Club Please call our customer service number and have your instructions and parts list ready to provide the model name, part name or factory number: Pacific Standard Time: 8:30 am - 4:30 pm Page # 1

2 Parts List Please read completely through the instructions and verify that all parts listed are present before beginning assembly. AH -Lower Headboard (1) AF -Lower Footboard (1) BH -Upper Headboard (1) BF -Upper Footboard (1) C -Mattress Side Rail (1) CL -Ladder Side Rail (1) DL -74 Lower Side Rail (2) DU -74 Guard Rail (2) Page # 2

3 Parts List Please read completely through the instructions and verify that all parts listed are present before beginning assembly. E- 57 Guard Rail (2) F -Mattress Support Slats (1) GB- Back Frame (1) GS Seat Frame (1) H- Sofa Cushion I- Front Guard Rail Post (1) J- Finial (8) KL- Left Ladder Support (1) KR- Right Ladder Support (1) KS- Ladder Step (6) L- Bed Connector Pins (4) ML- Sofa Left Bracket (1) MR- Sofa Right Bracket (1) Page # 3

4 Parts List Please read completely through the instructions and verify that all parts listed are present before beginning assembly. N- 4" Bolt (32+1 extra) O- 1 3/4" Bolt (14+1 extra) P- 3/4 " Allen Bolt Q- Flat Washer R- Lock Washer (16+1 extra) (16+1 extra) (16+1 extra) S- Barrel Nut (32+1 extra) T- Hook (2) U- 1 Wood Screws UU- 5/8 Wood Screws (32+1 extra) (6+1 extra) V-Floor Protectors (4) Allen Wrench (1) Touch Up Pen (1) Tool Required: Phillips Screwdriver, Allen Wrench (provided) Page # 4

5 ASSEMBLING UPPER BUNK WARNING LABEL ON HEADBOARD MUST ALWAYS FACE INWARD. NOTE: Please follow the instructions carefully to insure a safe and sturdy bed. Do not fully tighten the bolts until all rails and guardrails are attached. 1. Unpack the unit and confirm that you have all hardware and parts required. 2. Insert two Barrel Nuts (part S) into each end of the Mattress Side Rail (part C). Be sure that the long slot on the Barrel Nut is facing out and that the long groove is parallel to the Rail towards the end of the Side Rail. 3. Bolt the Mattress Side Rail (part C) to the Upper Headboard (part BH); by inserting two 4" Bolts (part N) through the bottom two holes in the post of the Headboard and into the Barrel Nut (part S) in the Mattress Side Rail (part C). Slat support must face in. as shown in detail # 1. Screw in only part way using the Allen Wrench provided. 4. Proceed to attach the two 74 Guard Rails (part DU) to the Upper Headboard (part BH). See detail # Repeat steps 2 thru 4 to attach the Mattress Side Rail and 74 Guard Rails (part C & DU) to the Upper Footboard (part BF). 6. Attach the Ladder Side Rail (part CL) to the Upper Headboard and Footboard (parts BH & BF). See detail #1. Note: The Ladder Side Rail has two holes for Front Guard Rail Post (part I). Page # 5

6 ASSEMBLING UPPER BUNK 7. Layout the Mattress Support Slats (part F) into the slots in the Mattress Side Rail (part C) and the Ladder Side Rail (part CL); Make sure that every slot has a slat. 8. Screw in each end of the slats using the 1 Wood Screw (part U) through the pre-drilled holes in the slat. As shown in detail #2. 9. Attach the Finial (part J) to each post of the Upper Headboard and Footboard (parts BH & BF). See detail # Mount the Front Guard Rail Post (part I) to the front facing side of the Ladder Side Rail (part CL) with two 1 3/4" Bolts (part O) through the front hole into the insert nuts on the Side Rail. As shown in detail #3. Page # 6

7 ASSEMBLING UPPER BUNK 11. Now attach two 57 Guard Rails (part E) from the Front Guard Rail Post (part I) to the Upper Headboard (part BH) using the 4" Bolts (part N) and Barrel Nuts (part S). As shown in detail #4. ASSEMBLING LOWER BUNK 12. Attach two 74 Lower Side Rails (part DL) to the Lower Headboard and Footboard (parts AH & AF); Using the 4" Bolts (part N) and Barrel Nuts (part S). See detail #5. Page # 7

8 13. Now attach the Sofa Right Bracket (part MR) to the Lower Headboard (part AH) with two 3/4" Bolts (part P) through the Lock Washers and Flat Washers (part R & Q) through the Bracket into the threaded inserts included in the Lower Footboard. As shown in detail # Repeat last step to attach the Sofa Left Bracket (part ML) to the Lower Footboard (part AF). ASSEMBLING LOWER BUNK 15. Attach the Seat Frame (part GS) to the Sofa Right Bracket (part MR), by inserting two 3/4" Bolts (part P) through the Lock Washers and Flat Washers (part R & Q) through the bottom two holes of the Bracket into the threaded inserts included in the bottom of the Seat Frame. Also secure with one 3/4" Bolt, Lock Washer and Flat Washer (part P, R & Q) from outside of Sofa Bracket. As shown in detail # Repeat the procedure to the Sofa Left Bracket (part ML). Page # 8

9 ASSEMBLING LOWER BUNK 17. In the same manner, attach the Back Frame (part GB) to the other end of the Sofa Left and Right Bracket (part ML & MR). See detail #8. CONNECTING BUNK BED 18. Insert Steel Connector Pins (part L) into holes of lower bunk posts; pins should extend 2" above post. With the help of a friend place top bunk over pins and onto lower bunk. See detail #9. Page # 9

10 ASSEMBLING LADDER 19. Screw Ladder Steps (part KS) to the Left Ladder Support (part KL) using the 1 3/4 Bolts (part O). See detail # Repeat last step with Right Ladder Support (part KR). 21. Attach in the Ladder Hook (part T) using two 5/8 Wood Screws (part UU) into the pre-drilled holes on the top of the Ladder Supports. See detail # Proceed to hook the Ladder securely over the top of the Ladder Side Rail (part CL), between the guardrail post and the Upper Footboard in the opening provided. Screw the hook to the Side Rail using two 5/8 Wood Screws (part UU) through the hole in the ladder hook. See detail # 12. ONLY USE LADDER IN THIS LOCATION AND SECURE WITH 2 SCREWS. Page # 10

11 ASSEMBLING TWIN BED NOTE: The Bunk Bed can be divided into Twin Bed and Sofa Bed. Be sure that you attach four Floor Protectors (part V) onto each bottom of post of parts BH & BF when form the Twin Bed. Guard Rails are not necessary. 23. Attach the Mattress Side Rail (part C) and Ladder Side Rail (part CL) to the Upper Headboard and Footboard (parts BH & BF); using the 4" Bolts (part N) and Barrel Nuts (part S). See detail # Refer step 9 through 11 to attach the Mattress Support Slats (part F) and Finials (part J) to the Twin Bed. As shown in detail # Repeat step 12 through 17 to assemble the Sofa Bed. 26. Attach the Finial (part J) to the hole with threaded inserts on each post of the Lower Headboard and Footboard (parts AH & AF). As shown in detail # Complete your assembly by placing on the Sofa Cushion (part H). A Touch-Up Pen has been provided to repair any small nicks or scratches that may occur during assembly or shipping. Your assembly should now be complete. Thank you for your purchase! Page # 11

12 WARNING!! ALWAYS USE GUARDRAILS ON BOTH LONG SIDES OF THE UPPER BUNK. IF THE BED WILL BE PLACED NEXT TO THE WALL, THE GUARDRAIL THAT RUNS THE FULL LENGTH OF THE BED SHOULD BE PLACED AGAINST THE WALL TO PREVENT ENTRAPMENT BETWEEN THE BED AND WALL. STRANGULATION HAZARD- Never attach or hang items to any part of the bed that are not designed for use with the bed; for example, but not limited to, hooks, belts and jump ropes. Prohibit more than one person on upper bunk. Maximum mattress thickness must not exceed 9. Surface of mattress must be at least 5 below the upper edge guardrails. Use only mattress which is long and 37 1/2 38 1/2 wide on upper bunk. Page # 12

13 Bunk Bed Safety Warning Follow the warning information that appears on the upper bunk end structure and on the carton. Do not remove warning label from bed. Always use the recommended size mattress or mattress support, or both to help prevent the likelihood of entrapment or falls. Surface of mattress must be at least 5 (127mm) below the upper edge guardrails. Do not allow children under 6 years of age to use the upper bunk. Periodically check and ensure that the guardrail, ladder and other components are in their proper position, free from damage, and that all connectors are tight. Do not allow horseplay on or under the bed and prohibit jumping on the bed. Always use the ladder for entering and leaving the upper bunk. Does not use substitute parts. Contact the manufacturer or dealer for replacement parts. Use of a night-light may provide added safety precaution for child using the upper bunk. Always use guardrails on both long sides of the upper bunk. The use of water or sleep flotation mattress is prohibited. Keep these instructions for future reference. Page # 13

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