Char-Broil 8401504 User manual

Assembly

Guide

Model Numbers:

(English)

42804526 • 8/16/2011

08401504

10401582

10401589

10401590

10401591

10401592

10401593

10401594

08401504-A2

08401504-A1

12401504

GAS (LP)

12401590

2 ASSEMBLY GUIDE

A, B, C, Assembly:

CAUTION: For your safety, before operating, Read Product Guide & Outdoor Cooking Guide

provided with this grill.

*SAFETY First…..Grill components may have sharp edges. Be careful when handling grill parts

during assembly. We suggest that you wear a sturdy pair of leather gloves while handling the grill parts.

BEFORE You Grill….

1. Read Product Guide & Outdoor Cooking Guide

2. Position Grill safely away from walls & structures

3. Pre– Heat Grill—15 minutes on High to season grill.

TOOLS REQUIRED FOR ASSEMBLY

NOTE….

Installer: Leave instructions with the grill.

Consumer: Retain instructions for reference.

Grill must be installed in accordance with local

codes…..

Designed for outdoor use on ly…

Read all instructions before operating…

Phillips Head

Screwdriver

(Not Supplied)

Small Adjustable

Wrench

BEFORE You begin assembly of your grill….

1. Carefully remove all components from the carton.

3. Please note that hardware used for assembly may not be shown actual size..

Familiarize yourself with the components and hardware used for assembly.

4. After removing components from the carton, split the carton open and use it as

a scratch-free work pad to assemble your grill.

Key Qty Description

A 1 Grill Lid

B 1 Cooking Grate

C 1 Trough

D 1 Burner

E 1

F 1 Firebox Bottom

G 1 Heat Shield

H 2 Side Lift Mechanism

I 1 Rear Lift Mechanism

J 1 Left Side Shelf

K 1 Right Side Shelf

Inner Reflector

L 1 Regulator Control Valve

M 2 Wheel

Key Qty Description

N 1 Hinge Set

O 1

P 1 Handle

Q 1 Logo Plate

R 1 Electrode with Wire

S 2 Side Shelf Bushings

T 2 Cooler Bag

U 2 Axle Rod

X. 1 RH Cart Fascia

Venturi Latch Assembly

V 1 Cart Base

W 1 LH Cart Fascia

Y 1 Match Holder

Z 2 Cooler Tray Kit

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.

Key Qty Description

AA 1 Handle Heat Sheild

BB 1 Lid Clasp

CC 2 Cart Foot

DD 10 Tube Plug

EE 1 Venturi Guard

FF 1 Piezo Ignitor Button

GG 2 Cooler Liner

... 1 Hardware Pack

... 1 Assembly Manual, English

... 1 Assembly Manual, Spanish

1 Assembly Manual, French

1 Product Guide, English

... 1 Product Guide, Spanish

... 1 Product Guide, French

...

3 ASSEMBLY GUIDE Grill Parts Diagram

EE O

4 ASSEMBLY GUIDE

Part Qty

A1– Cart RH Side Fascia

– Cart Base 1

– Cart Foot 2

–

Fasteners

#10x3/4"

(qty 2)

GRILL CART Assembly

Wheels 2 (qty 14)

screw

Axle Rod

(qty 2)

Wheel Retaining

Clip

Step 2: Carefully place the cart assembly on its

back. Install the Cart Feet (A4) by

threading them into the bushings as shown.

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.

Wheel Retaining Clip - install after

placing wheel and axle rod through

axle hole.

Axle Rod

Axle Hole

– Cart LH Side Fascia

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.

Wheel retaining clip -

Install after wheel and axle rod

through the hole as shown in

this direction only.

Clip shown properly installed.

Securely tighten the cart feet.

5 ASSEMBLY GUIDE

Part Qty

Fasteners

#10-24 x 1 1/4"

GRILL Assembly

(qty 4)

screw

B1–Heat Shield 1

B2–Fire Box Assembly 1

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.

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.

Right hand side

Firebox screw

holes

Left hand side

Firebox screw

holes

#10-24

(qty 4)

nut

#10 Lock

(qty 4)

washer

(qty 4)

Fiber Washer

Fiber washers

#10-24 x 1 1/4"

machine screws

#10 lock washers

#10-24 nuts

FRONT

Firebox Mounting Brackets

FRONT

NOTE: As viewed

from the front of

the grill.

NOTE: As viewed

from the front of

the grill.

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.

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.

Rear Pull Handle Pull Handle Locking Button

Assure FRONT marking on Heat Shield is to the front of the grill.

ASSEMBLY

6 ASSEMBLY GUIDE

Part Qty

B3– Hinge, RH 1

B4– Hinge, LH 1

B7– Handle 1

Fasteners

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.

(qty 8)

Fiber Washer

(qty 2)

Spacer for Lid

GRILL Assembly

LH side shown,

RH side similar.

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.

(qty 8)

10-24 Nut

B5– Grill Lid 1

(qty 12)

screw

10-24 x 5/8"

B6– Heat Shield 1

LH Hinge

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.

NOTE: The LH and RH hinge locations are referenced

from the rear of the firebox.

NOTE:

Assembling

the handle

may require

the assistance

of a helper.

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.

B3 - RH Hinge

B4 - LH Hinge

View from rear of firebox

Hinge section to attach

to Grill Lid (Top)

Hinge section to attach

to Firebox (Bottom)

Hinge Detail

7 ASSEMBLY GUIDE GRILL FINAL Assembly

Part Qty.

C1 – Side Shelf, RH

C2 – Side Shelf, LH 1

C3 – Trough 1

C4 – Cooking Grate

C6 – Cooler Bags/Coolers 2

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.

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.

C5 – Regulator Control Valve 1

C7 – Ignitor Wire

Part Qty.

Regulator Lock

1. Slide to rear

Regulator

2. Insert Regulator fully

into burner tube.

3. Release lock.

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