Page 1
Assembly
Guide
Model Numbers:
08401504
10401582
10401589
10401590
10401591
10401592
10401593
10401594
Propane cylinder
sold separately.
Allow approximately 45 minutes for assembly.
PROPANE
(English)
42804526 • 11/25/2009
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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 begin assembly of your grill….
1. Carefully remove all components from the carton.
2. Familiarize yourself with the components and hardware used for assembly.
3. Please note that hardware used for assembly may not be shown actual size..
4. After removing components from the carton, split the carton open and use it as
a scratch-free work pad to assemble your grill.
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.
TIPS & Tricks…...
First Take a moment to record the serial number here: _______________________________
When grilling, preheat your grill for 10 to 15 minutes with the lid down.
Go to charbroil.com to register your grill.-
After grilling—the grill can be turned on High for cleaning and burning off
the grate. - Use a wire brush to brush off the grate.
A light coat of oil on the grate will help prevent foods like fish and vegetables from
sticking to the grate.
TOOLS REQUIRED FOR ASSEMBLY
(Not Supplied)
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 only…
Read all instructions before operating…
Phillips Head
Screwdriver
Small Adjustable
Wrench
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3
ASSEMBLY GUIDE
Grill Parts Diagram
A
BB
AA
CC
J
B
C
D
E
K
Y
TT
FF
F
L
H
I
G
R
H
Z
EE
O
W
P
Q
V
GG
GG
U
M
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
L 1 Regulator Control Valve
M 2 Wheel
Inner Reflector
S
N
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
V 1 Cart Base
W 1 LH Cart Fascia
X. 1 RH Cart Fascia
Y 1 Match Holder
Z 2 Cooler Tray Kit
Venturi Latch Assembly
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
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.
X
DD
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ASSEMBLY GUIDE
Part Qty
A1–
–
A2
– Cart Base 1
A3
–
A4
–
A5
Cart RH Side Fascia
Cart LH Side Fascia
Cart Leveling Foot
Wheels
1
1
2
2
GRILL CART Assembly
#10x3/4"
screw
(qty 14)
Fasteners
Wheel Retaining
Clip
(qty 2)
Axle Rod
(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.
A1
A2
A3
Step 2: Carefully place the cart assembly on its
back. Install the Cart Leveling Feet (A4) by
threading them into the bushings as shown.
These leveling feet can be used to adjust your
grill when using it on uneven surfaces. After
installation of the leveling feet, place the cart
in the upright position.
A4
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.
Wheel Retaining Clip - install after
placing wheel and axle rod through
axle hole.
A3
Axle Hole
A5
Axle Rod
Completed Cart!
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5
ASSEMBLY GUIDE
–
B1
–
B2
Part Qty
Heat Shield
Fire Box Assembly
GRILL Assembly
1
1
Fasteners
#10-24 x 1 1/4"
screw
(qty 4)
#10-24
nut
(qty 4)
#10 Lock
washer
(qty 4)
Fiber Washer
(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.
Step 1 - Install the Heat Shield(B1) to
B1
Firebox Mounting Brackets
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.
#10-24 x 1 1/4"
machine screws
Fiber washers
Lid Clasp
B2
#10 lock washers
#10-24 nuts
Right hand side
Firebox screw
holes
Left hand side
Firebox screw
holes
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ASSEMBLY GUIDE
Part Qty .
B3– Hinge, RH 1
B4– Hinge, LH 1
B5– Grill Lid 1
B6– Heat Shield 1
B7– Handle 1
.
10-24 x 1/2"
screw
(qty 12)
GRILL Assembly
Fiber Washer
(qty 8)
Fasteners
10-24 Nut
(qty 8)
Spacer for Lid
(qty 2)
ASSEMBLY
Step 1 - Attach the Hinges (LH and RH) (B3 & B4) 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 #10-24x1/2" screws, 2 fiber washers and 2 #10-24
nuts as shown.
B4
LH side shown,
B2
RH side similar.
Step 3 - Attach the Heatshield (B6) and Handle (B7) to
the Grill Lid (B5) by aligning the screw holes in the handle
and heatshield with the corresponding holes in the Grill Lid.
Secure with 4 10-24 x 1/2" Screws and 4 fiber washers. Do not
over tighten the screws.
Step 2 - 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-
24x1/2" screws, 1 spacer and 2 #10-24 nuts as shown.
B5
B3
B6
B7
B2
B4
B5
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ASSEMBLY GUIDE
GRILL FINAL Assembly
Part Qty.
C1 –
C2 – Side Shelf, LH 1
C3 – Trough 1
C4 –
C5 – Regulator Control Valve 1
C6 – Cooler Bags/Coolers 2
Side Shelf, RH
Cooking Grate
1
1
C7 – Ignitor Wire
Part Qty.
1
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 pushbutton ignitor as shown.
Regulator Lock
1. Slide to rear
Regulator
C5
2. Insert Regulator fully
into burner tube.
3. Release lock.
C7
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
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© 2009 Char-Broil, LLC Printed in China • Columbus, GA 31902 •
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