assembly
guide
Model Number:
11601558
Propane cylinder
sold separately.
Estimated time required for assembly: 1 Hour
PROPANE
(English)
42804394 • 06/02/2010
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3
Grill Parts Diagram
K
ASSEMBLY GUIDE
H
FF
S
C
A
V
I
CC
T
X
J
G
L
W
D
B
DD
F
N
Y
O
E
P
R
U
GG
M
HH
Q
BB
Key Qty Description
BB
Z
AA
EE
Key Qty Description
Key Qty Description
CC
DD
EE
FF
GG
HH
...
1
1
1
2
1
1
1
1
1
1
1
1
1
1
Ignition Module
O
P
1
1
1
2
1
1
2
1
1
1
1
1
1
2
Rear Leg Set
A
B
C
D
E
F
1
1
1
1
1
1
1
1
1
1
1
1
2
1
Grill Lid
Electrode Wire
Ignitor Electrode
Lid Bumper
Front Leg Set
Grease Tray
Hubcap
Lower Body
Heat Tent
Q
R
Burner
Match Light Hole Cover
Grate Cleaning Tool
Hardware Pack
S
Hose, Valve, Regulator Assembly
Warming Rack
Axle
Tank Retainer Bolt
Ignition Harness
Bezel
T
U
V
W
X.
Y
Z
G
H
I
...
Assembly Manual, English
Heat Indicator
Cooking Grate
Match Holder
Tank Retainer Ring
Cart Base
Wind Shield
Inner Reflector
Towel Bar
...
Assembly Manual, Spanish, Optional
Assembly Manual, French, Optional
Grilling Guide
...
J
...
K
L
M
N
Lid Handle
Control Panel
Wheel
...
Product Guide, English
...
Product Guide, Spanish, Optional
Product Guide, French, Optional
AA
BB
Cart Bracket
...
Leg Cap
Control Knob
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.
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4
ASSEMBLY GUIDE
Part
GRILL CART Assembly
Qty
1
1
Tank Retainer Ring
A1–
.
A2– Cart Base
A3– Tank Retainer Bolt
A4– Front Leg Set
A5– Rear Leg Set
A6– Wheels
1
1
1
2
Wheel Retaining
Clip
1/4x20-1/2"
3/8-16 Nut
(qty 2)
(qty 2)
screw
(qty 4)
–
A7 Hubcap
2
Axle Bolt
(qty 2)
A1
A3
1/4-20 Nut
(qty 4)
Step 1
Assemble Tank Retainer Ring (A1) to the Cart Base (A2)
by aligning studs into corresponding holes. Secure with 4
each, 1/4-20 nuts using a small adjustable wrench, not
supplied.
Thread the Tank Retainer Bolt (A3) into the Tank
Retainer Ring(A1)
A2
1/4-20 Nuts
(4 each)
Step 2
Attach Front Leg Set (A4) to the Cart Base (A2) using 2 1/4-20 screws. Attach Rear Leg Set (A5) to
the Cart Base (A2) in the same manner, using 2 1/4-20 screws.
Attach 2 Axle Bolts to the Rear Leg Set (A5), thread a 3/8-16 nut as shown and tighten securely using
a small adjustable wrench.
Slide a Wheel (A6) over an Axle Bolt and secure using a Wheel Retaining Clip. Repeat for other side.
Position and Snap into place the Wheel Hubcaps (A7).
After cart assembly, if
your cart does not sit
level, use these screws to
adjust the cart.
A5
Axle Nut
Axle Bolt
3/8-16
A4
A2
Wheel
Retaining
Clip install after
placing wheel on
the axle.
1/4-20 Screws
(4 each)
A7
A6
Position wheel
as shown
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5
ASSEMBLY GUIDE
GRILL CART Assembly
.
Part
A8 Cart Bracket
Qty
1
–
1/4x20-2"
screw
(qty 4)
–
A9 Leg End Cap
2
1/4-20 Nut
(qty 4)
#10x3/8"
screw
(qty 2)
Step 3 - Carefully turn the Cart Assembly over
and allow it to rest on the tops of the leg
assemblies. Assemble the Cart Bracket (A8) to
the Cart Assembly by by inserting 4 each 1/4-
20x2" screws int0 into corresponding holes as
shown. Allow the Cart Bracket to rest on the
floor, this will help with alignment. Secure with 4
each, 1/4-20 nuts using a small adjustable
wrench, not supplied. FINGER TIGHTEN ONLY
AT THIS TIME. The bracket will be tightened in
step B2.
Be sure to install Cart Bracket (A8) on the side
opposite of the ignition module bracket. Once
complete -leave the cart in the upside down
position.
Lastly, insert the Leg End Caps (A9) into the front
legs and secure with 1 each #10x3/8" screw.
A8
Ignition Module
Bracket
#10x3/8" screws
A9
1/4-20x2"
screws
Place the Lower Body on the carton
pad upside down in preparation for
the next step.
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6
GRILL BODY Assembly
ASSEMBLY GUIDE
Part
Qty.
B1– Lower Body
B2– Wind Shield
B3– Grill Lid
1
1
1
10-24x3/8"
screw
(qty 3)
10-24 Nut
(qty 10)
Fiber Washer
(qty 5)
1/4-20 Nut
(qty 2)
1/4-20x3/4"
Hinge
screw
(qty 2)
ASSEMBLY
Step 1 - Attach the Lower Body (B1) to the Cart Assembly
by aligning the studs on the bottom of the grill with the
corresponding holes in the tops of the leg assemblies. Secure
Step 3 - Attach the Wind Shield (B2) to the Lower Body
(B1) by aligning the holes in the panels with the corresponding
holes in the Lower Body. Secure with 3 10-24 nuts, 3 10-
with 7 each 10-24 nuts. A Nut Driver (not supplied) will work 24x3/8" Screws, and fiber washers. The Wind Shield will
nicely for this step.
rest inside the Lower Body.
10-24x3/8"
Screws
(3 each)
10-24
Nuts
(3 each)
B2
Studs
located on
Lower
Body.
B1
B1
Fiber
Washer
(3 each)
Step 2 - With the legs assembled to the Lower
Body, tighten the 4 screws holding the Cart
Bracket in place. Once complete, turn the grill over
to the upright position.
Step 4 - Attach the Grill Lid (B3) by aligning the hinge
holes in the lid to the matching holes in the Wind Shield
(B2). Insert 2 Hinge Screws into the holes and secure with 2
1/4-20 nuts and two Fiber washers from the inside of the
grill.
Cart
Bracket
1/4-20x3/4"
Hinge
Screws
B3
B1
(2 each)
Fiber
Washer
(2 each)
1/4-20
Nuts
(2 each)
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7
GRILL FINAL Assembly
ASSEMBLY GUIDE
NOTE: The Cooking Grate may have sharp edges. Be
very careful when handling the Cooking Grate. You
should wear gloves when handling the Cooking Grate.
The cooking grate ridges should run from front to back of
the grill as shown below. Be sure that the cooking grate
rests squarely on the brackets spaced around the lower
body. This will make for easier grate cleaning as well.
Part
Qty.
Heat Tent
C1 –
1
1
1
1
1
C2 – Cooking Grate
C3 – Warming Rack
C4 –
Control Knob
C5 – Grease tray
Step 1 - With the Grill Lid open, place the legs of the Heat Tent (C1) into the matching impressions in the Lower Body. Next,
Place the Cooking Grate (C2)into the Lower Body. The cooking grate ridges should run from front to back of the grill as shown
below. Be sure that the cooking grate rests squarely on the three brackets spaced around the Lower Body.
Ridges front to
back
C1
C2
Step 2 - Place the Warming Rack (C3) into position by first hooking the center pins into the windshield, then rotate the
warming rack down into position. Next, Press the Control Knob (C4) onto the valve stem.
Install the Grease Tray (C5) by sliding the tray onto the Grease Tray Rails from the rear of the grill. Note: The grease tray
rests between the grease tray rail stops. See detail shown in Figure A.
C3
Note: The control
knob may be
factory assembled
Grease
Tray
Rails
C5
C4
Fig. A
Grease
Tray
Rail Stops
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8
GRILL FINAL Assembly
ASSEMBLY GUIDE
Part
Battery
Electronic Ignition Module
Lid Handle
Qty.
1
1
1
C6 –
C7 –
C8 –
10-24x3/8"
Fiber Washer
(qty 2)
screw
(qty 2)
NOTE: The Ignition wiring shown below will only fit into the module one way. Be sure the
wires are routed away from the heat source. Do not allow the wires to rest against hot areas of
the grill.
Step 3 - Install the Electronic Ignition Module, Unscrew the Battery Cap and module nut from the module. Insert the
module into the module bracket. Secure with the module nut. Install the Battery (C6) in the Electronic Ignition Module
(C7) with the negative end first. Screw the Battery Cap back into place. Install the ignition wires as shown below.
Battery
Ignitor
Electrode
C6
Ignitor Wire to
Ignitor Electrode
C7
Battery
Cap
Module
Nut
Ignition Wires from
Control Panel
Rear of Ignition
Module shown
Step 4 - Install the Lid Handle (C8) with 2 10-24x3/8" screws and 2 fiber washers as shown. Install the propane cylinder.
Be sure to loosen the tank retaining bolt far enough to allow the cylinder to rest securely on the cart base. Tighten the tank
retaining bolt and attach the propane regulator (not shown) when you are ready to use the grill.
Cylinder valve
facing RH side
of grill.
C8
10-24x3/8"
Screws
(2 each)
Fiber
Washer
(2 each)
20lb.Propane
Cylinder
Loosen Tank Retaining Bolt,install cylinder, then tighten.
Congratulations! You have successfully completed the assembly of your grill. Prior to using your grill, be sure to follow the
leak check instructions found in the Care and Use Guide.
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