Charbroil 461644304 Owner's Manual

1

2

4

EXPLODED DIAGRAM

Part appearance may differ slightly.

PARTS LIST

3

Position leg assemblies as shown and attach mid brace to back
legs using two screws (D). Make sure holes on mid brace face

inward and the label faces outward.

7

To attach control panel assembly to cart, insert valves into burner tubes and attach control panel to legs using two screws (D) and hex nuts (F), but

NOT FULLY TIGHTEN Note illustration of proper valve/burner tube engagement.

into control panel.

. Insert two screws (G) from inside grill bottom, through base plate,

DO

19

Key Qty Description Part #

1 1 Grill Lid .........................80000197

3

14

5

26

13

8

36

8

6

7

27

35

19

20

32

21

22

37

15

2 1 Top Lid Hinge, Right...............80000232

3 1 Top Lid Hinge, Left ................80000234

4 1 Logo Plate ......................80000227

5 1 Handle .........................80000220

6 1 Grill Bottom......................80000195

7 2 Grill Bottom Bracket ...............80000190

8 2 Bottom Lid Hinge .................80000233

9 1 Tank Support Bracket..............80000177

10 1 Tank Retainer Bracket .............80000788

11 2 Wheel ..........................80000230

12 2 HubCap........................80000231

13 1 Burner Assembly .................80000161

14 1 VapoRISER Bar ..................80000224

15 1 Control Panel ....................80000770

16 1 Valve/Hose/Regulator..............80000205

17 1 Leg Assembly, Right...............80000171

18 1 Leg Assembly, Left ................80000170

19 2 Side Shelf.......................80000184

Key Qty Description Part #

27 1 Warming Rack ...................80000223

28 1 Grease Cup .....................80000731

29 2 Leg Extender ....................80000229

30 1 Ignitor ..........................80000764

31 2 Control Knob ....................80000214

32 1 Tool Hook .......................80000211

33 1 Grease Clip .....................80000736

34 1 Ignitor Wire......................80000737

35 1 Side Shelf Grip ...................80000191

36 1 Base Plate ......................80000241

37 1 Hose Shield .....................80000206

1 Hardware Pack...................80000769

1 Assembly Instructions .............80000956

1 Use & Care Manual ...............80000790

D

Qty. 2

4

D

Mid Brace

D

D

Qty. 2

G

Qty. 2

F

Valve

Qty. 2

G

Burner Tube

G

Base Plate

21

20

22

12

11

9

Some parts may be preassembled.

20 2 Shelf Bracket, Left Front, Right Rear . . 80000727

11

10

33

12

18

25

28

29

17

24

31

34

30

16

23

7

21 2 Shelf Bracket, Right Front, Left Rear . . 80000729

22 2 Shelf Mounting Bracket ............80000783

23 1 Front Panel......................80000192

24 1 Front Panel Extension .............80000210

25 1 Mid Brace .......................80000176

26 1 Cooking Grate ...................80000221

G

Qty. 2

5

Burner Assembly

Grill Bottom

E

G

E

Do not fully
tighten

D

F

F

Control
Panel
Assembly

D

Do not fully
tighten

See parts list for cross reference.

1

Grill Bottom
Bracket

A

Tab into
small hole

A

Attach the bracket to the right leg assembly plate using two screws (A). Tab on bracket fits into small hole
between screw holes on plate. Attach mounting bracket using four screws (A). Push leg extenders into ends of legs.

grill bottom

Leg Assembly, Right

shelf

Shelf Mounting
Bracket

Leg Assembly, Right

Align tab
with
notch

A

Place grill bottom onto grill bottom
brackets and align mounting holes.
Insert four screws (E), with washers (H),
from inside grill bottom, through
brackets. Secure with four hex nuts (F).

E

Qty. 4

H

H

H

461644304
ASSEMBLY MANUAL

N

F

Qty. 6

2

B

Qty. 2

A

Leg Extender

Attach the grill bottom bracket to the left leg assembly plate using two screws (A)
screw holes on plate.
Insert axle bolts (B) through wheels into bracket. Secure with hitch pins (C). Snap hub caps onto wheels.

Grill Bottom
Bracket

A

Tab into
small hole

Hub Cap

C

Attach shelf mounting bracket using four screws (A). Place tank support bracket between ends of legs.

Shelf Mounting
Bracket

Leg Assembly, Left

B

C

Tank
Support
Bracket

. Tab on bracket fits into small hole between

Leg Assembly, Left

C

Wheel

B

A

Qty. 4

Qty. 4

6

A

Qty. 4

P

Qty. 4

F

F

Attach bottom lid hinges to back of grill bottom. Insert two screws (A),
with washers (P), from inside grill bottom into each hinge.

A

P

P

A

Bottom Lid Hinge

THIS GRILL IS FOR
OUTDOOR USE ONLY

CAUTION:

statements, assembly instructions, and use
and care directions before attempting to
assemble and cook.

INSTALLER/ASSEMBLER:

instructions with consumer.

CONSUMER:

reference.

!

Failure to follow all manufacturer’s
instructions could result in serious personal
injury and/or property damage.

!

Some parts may contain sharp edges –
especially as noted in the manual! Wear
protective gloves if necessary.

If you have any questions or need assistance
during assembly, please call 1-800-241-7548.

Read and follow all safety

Leave these

Keep this manual for future

461644304 / 80000956 (10-15-03)

Qty. 6

Qty. 2

8

Snap ignitor into control panel and press control knobs onto valves. Attach round end of ignitor wire to ignitor and flat end to
electrode beneath grill bottom.

Control Knobs

11

Position front panel between front legs. Insert four fasteners (M) through edges
of panel and into legs.

Place top lid hinges inside bottom hinges and align

14 17

holes. Insert hinge pins (O) and secure with hitch
pins (C).

O

LP tank is sold separately. Fill and leak check before attaching to grill and regulator.

Center LP tank on tank support bracket with collar opening facing to front of grill. Lift tank retainer bracket, position tank
collar under it, then lower bracket onto collar. Tighten wing nut to secure bracket.

Ignitor

Ignitor Wire

Front
Panel

FRONT

M

Qty. 4

BACK

M

O

C

Qty. 2

CAUTION

C

Tank collar opening must face to front of cart
once tank is attached.

Qty. 2

Failure to install tank correctly may allow gas
hose to be damaged in operation, resulting in the
risk of fire.

Tank Retainer
Bracket

O

Tank Collar

9

I

Qty. 1

Insert one screw (E) into each side of grill bottom from the outside.
On the inside of grill bottom attach a hex nut (F) to each screw (E).
Place VapoRISER Bar inside grill bottom, resting on screws.
Attach tank retainer bracket to inside of left rear leg using one bolt
(I) and one wing nut (J). Do not fully tighten wing nut (J) until LP
tank is installed ( ).tank not included

E

J

Qty. 2

E

F

F

VapoRISER Bar

E

12

Insert tabs on front panel extension into slot in front panel. Secure extension to
legs using two fasteners (M).

BACK

Qty. 2

M

M

15

Place cooking grate into grill bottom. Insert ends of
warming rack pivot wire into holes on side of grill lid.
Insert warming rack leg wires into holes in side of
grill bottom. From beneath right shelf, insert tool
hooks into holes in front edge of shelf.

Warming
Rack

Tool Hook

Cooking
Grate

Qty. 1

10

J

Attach right front and right rear shelf brackets beneath side shelf using six screws (E). Align ends of shelf
brackets on the outsides of the mounting bracket and secure with four bolts (K). Slide shelf grip over end of side
shelf and insert two rubber darts (L) through holes in grip and shelf. NOTE: Only one shelf grip is provided and
should be attached to right side shelf. Repeat shelf assembly procedure for left side shelf, using the left front
and left rear shelf brackets.

Right Rear
Shelf Bracket

F

Qty. 2

Tank
Retainer
Bracket

I

Right Front
Shelf Bracket

E

Qty. 12

K

Qty. 8

FRONT

Position right and left top lid hinges inside grill lid. Insert four screws (A) through outside of lid into hinges. NOTE: When

13

facing the back of the lid, the hinge with the wider-spaced holes should be to the right side. Insert two bolts (N) into
handle, then into holes in front of grill lid. Secure from inside of lid with two washers (P) and hex nuts (F). Snap logo
plate into grill lid.

Front Panel Extension

P

A

16

Insert grease cup into grease clip, then hang grease clip from drain hole in grill bottom. Fully tighten control panel screws now.

CAUTION

• Failure to install cup in clip will cause
hot grease to drip from bottom of grill
with risk of fire or property damage.

Tank Collar

LP Gas Tank

(not included)

Fully tighten control
panel screws now.

Right Side Shelf
(Lighting instructions
printed on shelf)

E

L

Side Shelf Grip

(Right side only)

L

Qty. 2

Logo Plate

Top Lid Hinge, Left

Grill Lid

Top Lid Hinge, Right

A

Qty. 4

F

Qty. 2

P

P

Qty. 4

N

Qty. 2

HARDWARE PACK

There may be extra screws.

A

B

C

D

E

F

Grease Clip

Grease
Cup

G

H

See Use & Care manual to perform the “Burner Flame Check” and for

important safety instructions before using.

I

J

K

L

M

N

O

P

K

K

N

Handle

N

F

Handle

Qty. 20

Qty. 2

Qty. 4

Qty. 4

Qty. 18

Qty. 9

Qty. 4

Qty. 4

Qty. 1

Qty. 1

Qty. 8

Qty. 2

Qty. 8

Qty. 6

Qty. 2

Qty. 2

ASSEMBLY INSTRUCTIONS • 461644304