Assembly
Guide
Model Numbers:
08401504-A1
08401504-A2
08401504
10401582
10401589
10401590
10401591
10401592
10401593
10401594
12401504
12401590
GAS (LP)
(English)
42804526 • 8/16/2011
Download from Www.Somanuals.com. All Manuals Search And Download.
3
Grill Parts Diagram
ASSEMBLY GUIDE
BB
A
B
AA
CC
J
D
E
C
Y
K
T
FF
F
L
H
I
G
Z
R
H
EE
O
W
P
Q
X
V
GG
GG
U
M
S
N
DD
Key Qty Description
Key Qty Description
Key Qty Description
N
O
P
Q
R
S
T
1
1
1
1
1
2
2
2
1
1
1
1
2
Hinge Set
Venturi Latch Assembly
Handle
AA
BB
CC
1
1
2
Handle Heat Sheild
Lid Clasp
Cart Foot
A
B
C
D
E
F
G
H
I
1
1
1
1
1
1
1
2
1
1
1
1
2
Grill Lid
Cooking Grate
Trough
Logo Plate
DD 10
Tube Plug
Burner
Electrode with Wire
Side Shelf Bushings
Cooler Bag
EE
FF
GG
...
...
...
...
...
...
...
1
1
2
1
1
1
1
1
1
1
Venturi Guard
Piezo Ignitor Button
Cooler Liner
Inner Reflector
Firebox Bottom
Heat Shield
Side Lift Mechanism
Rear Lift Mechanism
Left Side Shelf
Right Side Shelf
Regulator Control Valve
Wheel
U
V
W
X.
Y
Z
Axle Rod
Hardware Pack
Cart Base
Assembly Manual, English
Assembly Manual, Spanish
Assembly Manual, French
Product Guide, English
Product Guide, Spanish
Product Guide, French
LH Cart Fascia
RH Cart Fascia
Match Holder
Cooler Tray Kit
J
K
L
M
NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from
those on your particular model. However, the method of assembly remains the same.
Download from Www.Somanuals.com. All Manuals Search And Download.
4
ASSEMBLY GUIDE
GRILL CART Assembly
Fasteners
Part
Qty
Cart RH Side Fascia
Cart LH Side Fascia
– Cart Base
– Cart Foot
A1–
1
–
1
1
2
A2
A3
A4
#10x3/4"
screw
Wheel Retaining
Clip
Axle Rod
(qty 2)
–
A5 Wheels
2
(qty 14)
(qty 2)
Step 1: Assemble the LH and RH Side Fascia (A1 & A2)
to the Cart Base (A3) by aligning screw holes in the
fascias with corresponding holes in the cart base.
Secure with 7 each, #10x3/4 screws (7 per side) using a
phillips screwdriver. Repeat for other side. NOTE: The
lift handles are shown in the up position. You can
complete steps 1 and 2 with the handles lowered if
desired.
Step 2: Carefully place the cart assembly on its
back. Install the Cart Feet (A4) by
threading them into the bushings as shown.
Securely tighten the cart feet.
A4
A3
A1
A2
A3
Step 3: Assemble the Wheels (A5) to the Cart Base
(A3) by first sliding an axle rod through the wheel,
then sliding the axle rod through the axle rod holes
in the cart base. Secure with a wheel retaining clip.
Repeat for the other side.
Axle Hole
Axle Rod
Clip shown properly installed.
A3
A5
Wheel retaining clip -
Install after wheel and axle rod
through the hole as shown in
this direction only.
Wheel Retaining Clip - install after
placing wheel and axle rod through
axle hole.
Download from Www.Somanuals.com. All Manuals Search And Download.
5
GRILL Assembly
ASSEMBLY GUIDE
Fasteners
Part
Qty
–
B1 Heat Shield
1
–
B2 Fire Box Assembly
1
#10-24 x 1 1/4" #10-24
#10 Lock Fiber Washer
screw
(qty 4)
nut
washer
(qty 4)
(qty 4)
(qty 4)
Note: Before beginning this step of the
assembly, raise the two side lifts to their
highest position by pressing the button at the
top of the handle and pulling upward on the
handle.
B1
The pull handle at the rear of the cart also has
a locking button, press the button to raise or
lower the pull handle into the desired
position. During Assembly, the rear pull
handle should remain in its lowered position.
Firebox Mounting Brackets
Step 1 - Install the Heat Shield(B1) to
the firebox mounting brackets by
engaging the tabs into the slots located
in the mounting brackets as shown on
the right.
Rear Pull Handle
Pull Handle Locking Button
Assure FRONT marking on Heat Shield is to the front of the grill.
Step 2 - Install the Fire Box Assembly(B2) to the cart by first placing the firebox assembly onto the
firebox mounting brackets. Be sure that the lid clasp is toward the front of the cart. Align the firebox
screw holes with the corresponding holes in the mounting brackets. Insert 4 #10-24 x 1 1/4" machine screws
and 4 fiber washers through the firebox and mounting brackets. Secure with 4 #10-24 nuts and 4 #10
lock washers from below the mounting brackets as shown below.
#10-24 x 1 1/4"
machine screws
Right hand side
Firebox screw
holes
Fiber washers
NOTE: As viewed
from the front of
the grill.
B2
NOTE: As viewed
from the front of
the grill.
Left hand side
Firebox screw
holes
FRONT
#10 lock washers
#10-24 nuts
Download from Www.Somanuals.com. All Manuals Search And Download.
6
GRILL Assembly
ASSEMBLY GUIDE
Fasteners
Part
Qty
B3– Hinge, RH
B4– Hinge, LH
B5– Grill Lid
B6– Heat Shield
B7– Handle
1
1
1
1
1
10-24 x 5/8"
screw
Spacer for Lid
(qty 2)
Fiber Washer 10-24 Nut
(qty 8)
(qty 8)
(qty 12)
ASSEMBYL
Step 4 - Attach the Grill Lid (B5) to the Hinges by
aligning the screw holes on the grill lid with the
corresponding holes in the hinges. Secure with 2 each #10-
24x5/8" screws, 1 spacer and 2 #10-24 nuts as shown.
Step 3 - Attach the Hinges (LH and RH) (B4 & B3) to the
Firebox Bottom by aligning the screw holes on the bottom of
the grill with the corresponding holes in the hinges. Secure
with 2 each #10-24x5/8" screws, 2 fiber washers and 2 #10-24
nuts as shown.
NOTE: The LH hinge is mounted to the left side
of the firebox bottom as viewed from the rear of
the firebox. See Hinge Detail below.
B5
B4
LH Hinge
B3 - RH Hinge
View from rear of firebox
B2
LH side shown,
RH side similar.
B4 - LH Hinge
Step 5 - Attach the Heatshield (B6) and Handle (B7) the
Grill Lid (B5) by aligning the screw holes in the handle to and
heatshield with the corresponding holes in the Grill Lid.
Loosely install 1 10-24 x 5/8" Screw and 1 fiber washer on the
LH side of handle. Loosely install a second 10-24 x 5/8" Screw
and 1 fiber washer on the RH side of handle. Now install the
remaining 2 10-24 x 5/8" Screws and 2 fiber washers. When all
four screws and fibers washer have been started, tighten each
screw, but do not over tighten the screws.
B2
NOTE:
Assembling
the handle
B7
NOTE: The LH and RH hinge locations are referenced
from the rear of the firebox.
may require
the assistance
of a helper.
Hinge Detail
Hinge section to attach
to Grill Lid (Top)
Hinge section to attach
to Firebox (Bottom)
B6
B5
Download from Www.Somanuals.com. All Manuals Search And Download.
7
GRILL FINAL Assembly
ASSEMBLY GUIDE
Part
Qty.
Part
Qty.
Side Shelf, RH
C1 –
1
1
C7 – Ignitor Wire
C2 – Side Shelf, LH
C3 – Trough
1
1
1
1
2
C4 –
Cooking Grate
C5 – Regulator Control Valve
C6 – Cooler Bags/Coolers
Step 1 - Install the Regulator Control Valve (C5) by first sliding the regulator lock toward the rear of the grill, inserting
the Regulator Control Valve fully into the exposed burner tube, and then releasing the regulator lock. Next, press the end of
the Ignitor Wire (C7) onto the push button ignitor as shown.
Regulator Lock
Regulator
C7
C5
2. Insert Regulator fully
into burner tube.
3. Release lock.
Step 2 - Place the Side Shelves RH and LH (C1 & C2) into position by aligning the mounting rods with the bushing located
in the firebox bottom. Press the shelves into place firmly. Place the Trough (C3) into the Firebox Bottom, then place the
Cooking Gate (C4) into the Trough. The Cooler Bags (C6) rest on the bottom shelf of the grill cart, as shown.
C4
C2
C3
C1
C6
C6
Download from Www.Somanuals.com. All Manuals Search And Download.
© 2011 Char-Broil, LLC • Columbus, GA 31902 • Printed in China
Download from Www.Somanuals.com. All Manuals Search And Download.
|