Charbroil 461644604 Owner's Manual

2

1

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

43

38

3

41

40

42

44

8

26

14

13

46

5

36

8

6

22

7

27

19

20

21

37

35

32

15

Key Qty Description Part #

1 1 Grill Lid .........................80000198

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......................80000754

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

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

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

10 1 Tank Retainer Bracket .............80000265

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

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

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

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

15 1 Control Panel ....................80000215

16 1 Valve/Hose/Regulator..............80000204

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

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

19 1 Side Shelf.......................80000185

Key Qty Description Part #

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

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

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

30 1 Ignitor ..........................80000733

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

38 1 Sideburner Shelf..................80000187

39 1 Sideburner Shelf Mounting Bracket . . . 80000181

40 1 Sideburner ......................80000166

41 1 Sideburner Electrode ..............80000168

42 1 Sideburner Pan ..................80000165

43 1 Sideburner Grate .................80000163

44 1 Sideburner Control Knob ...........80000734

45 1 Sideburner Ignitor Wire ............80000735

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

45

20

39

12

11

9

Some parts may be preassembled.

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

11

10

33

12

18

25

28

24

17

29

23

30

31

34

16

7

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

22 1 Folding Shelf Mounting Bracket ......80000783

23 1 Front Panel......................80000193

24 1 Front Panel Extension .............80000207

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

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

46 1 Temperature Gauge with Nut ........80000237

1 Hardware Pack...................80000767

1 Assembly Instructions .............80000957

1 Use & Care Manual ...............80000739

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

folding shelf

Folding Shelf
Mounting Bracket

Leg Assembly, Right

Slotted
Hole

A

Align tab
with
notch

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

461644604
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. sideburner shelf
ends of legs. 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 mounting bracket using four screws (A). Place tank support bracket between

Shelf Mounting
Bracket

Leg Assembly, Left

B

C

Tank
Support
Bracket

. Tab on bracket fits into small hole between

Round
Hole

Leg Assembly, Left

Wheel

C

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

461644604 / 80000957 (02-02-04)

Qty. 6

Qty. 2

8

Ignitor

Snap ignitor into control panel and press control knobs onto valves. Attach round end of short ignitor wire to ignitor and flat
end to main burner electrode beneath grill bottom. Attach round end of long sideburner ignitor wire to side of ignitor. Flat
end will be attached in a later step.

Control Knobs

11

Attach sideburner electrode to shelf with one screw
(G). Snap valve cup into shelf and press sideburner
control knob onto valve. Insert sideburner into shelf,
making sure threaded stud is in small hole. Slide
burner tube onto sideburner valve.

below for proper tube-to-valve engagement.

Secure burner to shelf using one hex nut (F) on
threaded stud. Beneath shelf, attach sideburner
ignitor wire to sideburner electrode.

See illustration

Sideburner

Sideburner
Electrode

G

Electrode
Hole

Sideburner
Knob

14

Position right and left top lid hinges inside grill lid. Insert four screws (A) through washers (P), then through outside of lid into hinges. NOTE: When 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 hex nuts (F). Snap logo plate into grill lid. Remove nut from temperature gauge and insert gauge into center hole in grill
lid. Secure with nut inside lid.

P

A

P

17

Insert grease cup into grease clip, then hang grease clip from drain hole in grill bottom.

Fully tighten control panel screws now.

Fully tighten control
panel screws now.

Grease Clip

Long Ignitor Wire

Insert one screw (E) into each side of grill bottom from the outside.

9

Qty. 1

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

I

Short Ignitor Wire

E

Qty. 2

J

E

F

F

VapoRISER Bar

E

Proper tube-to-valve
engagement.

F

Valve Cup

F

Qty. 1

G

Qty. 1

Temperature
Gauge

N

Logo Plate

F

Top Lid Hinge, Left

Grill Lid

Top Lid Hinge, Right

Temperature
gauge Nut

A

Qty. 4

F

Qty. 2

P

Qty. 4

N

Qty. 2

Handle

CAUTION

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

18

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.

Tank Retainer
Bracket

Tank Collar

Grease
Cup

CAUTION

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

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

Qty. 1

10

J

Attach front and 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 sideburner shelf, using the remaining front
and rear shelf brackets.

Rear
Shelf Bracket

F

Qty. 2

Tank
Retainer
Bracket

I

Front
Shelf Bracket

E

Qty. 12

K

Qty. 8

Burner Tube

12

Front
Panel

Valve

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

Sideburner
Ignitor Wire

BACK

Handle

15

N

O

C

F

Place top lid hinges inside bottom hinges and align
holes. Insert hinge pins (O) and secure with hitch
pins (C).

O

Tank Collar

LP Gas Tank

(not included)

Qty. 2

C

Qty. 2

Right Side Shelf
(Lighting instructions
printed on shelf)

E

L

Side Shelf Grip

(Right side only)

L

Qty. 2

13

M

Qty. 4

FRONT

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

BACK

M

Qty. 2

M

16

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. Place sideburner grate onto sideburner
shelf. From beneath right shelf, insert tool hooks
into holes in front edge of shelf.

Sideburner
Grate

Warming
Rack

O

HARDWARE PACK

A

C

Qty. 20

B

Qty. 4

D

See Use & Care manual to perform the
“Burner Flame Check” and for important
safety instructions before using.

There may be extra hardware.

E

Qty. 18

F

I

K

Qty. 8

L

M

Qty. 6

N

O

Qty. 2

K

K

FRONT

Front Panel Extension

M

Cooking
Grate

Tool Hook

Qty. 2

Qty. 4

Qty. 10

G

Qty. 5

H

Qty. 4

Qty. 1

J

Qty. 1

P

Qty. 2

Qty. 8

Qty. 2

ASSEMBLY INSTRUCTIONS

461644604