Harbor Freight Tools 91250 Assembly And Operating Instructions Manual

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-B-Q Charcoal Grill-B-Q Charcoal Grill

-B-Q Charcoal Grill-B-Q Charcoal Grill

-B-Q Charcoal Grill

ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www.harborfreight.com

Copyright © 2004 by Harbor Freight Tools®. All rights reser ved. No por tion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor F reight Tools.

For technical questions and replacement parts, please call 1-800-444-3353

91250

SKU 91250 Page 2

Specifications

Save This Manual

You will need the manual for the saf ety warnings and precautions, assembly
instructions, operating and maintenance procedures, parts list and diagram. K eep
your inv oice with this man ual. Write the inv oice number on the inside of the front
cover. Keep the manual and inv oice in a safe and dry place for future reference.

Safety Warnings and Precautions

W ARNING: When using this BBQ, basic safety precautions should al ways be
followed to reduce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep assembly and operation area clean. Cluttered areas invite injuries.

2. Observe work area conditions. Do not use in damp or wet locations. Don’t
expose to rain. Keep area well lighted.

3. Keep children awa y. Children m ust nev er be allo wed in the area when the
BBQ is in use or remains hot.

4. Store idle equipment. When not in use, BBQ must be stored in a dry
location to inhibit rust.

5. Use eye protection. Always wear ANSI approved impact safety goggles
when assembling this product.

6. Do not overreach. Keep proper footing and balance at all times. Do not
reach over or across BBQ when in use or hot.

7. Stay alert. Watch what you are doing, use common sense. Do not use when
you are tired.

8. Use recommended lighting fuel. Use approved barbecue lighting fuel to
ignite briquettes. Never use Gasoline or other non-recommended

flammable liquids.

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SKU 91250 Page 3

9. Extinguish Briquettes when finished. Do not dump hot briquettes; a fire
may result. Extinguish briquettes with water and make sure they are cold
before disposing of them properly .

10. Use the BBQ on a level surface, well away from any flammable materials.
A level surface is required for proper stability of this BBQ. Do not ignite within
5 feet of any flammable materials, such as overhanging shrubbery or awning,
draperies, buildings etc.

11. Check for damaged parts. Before using the BBQ, any part that appears
damaged should be carefully checked to determine that it will work properly
and perform its intended function. Any part that is damaged must be repaired
properly or replaced by a qualified technician prior to use.

12. Do not leave the BBQ unattended while hot. Never leave the BBQ
unattended by a qualified adult while it is hot. Se vere injury, fire, or damage to
property may result.

13. Avoid Burns. Never move the BBQ while it is hot. Use long handled utensils
(availab le from Harbor Freight Tools) to avoid b urns or splatters . Avoid spilled
grease into the hot briquettes, as flame up may result.

14. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warr anty . Only use
accessories intended for use with this tool. Approved accessories are
availab le from Harbor Freight T ools .

15. Do not operate tool if under the influence of alcohol or drugs. Read
warning labels on prescriptions to determine if y our judgment or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.

16. Maintenance. For y our safety, service and maintenance should be perf ormed
regularly by a qualified technician.

17. Charcoal produces carbon monoxide (CO) when it is burned. CO is a

colorless, odorless gas that can accumulate to toxic levels in closed
envir onments. T o reduce the risk of CO poisoning: Never b urn charcoal
inside of homes, vehicles, tents or campers. Charcoal should never be
used indoors, even if ventilation is provided.

Note: Charcoal produces CO fumes until the charcoal is completely

extinguished; do not store the Grill indoors with freshly used coals.

Warning: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions and situations that ma y occur. It
must be understood by the operator that common sense and caution are factors
which cannot be built into this product, b ut must be supplied by the operator .

SKU 91250 Page 4

Unpacking

When unpacking, please compare parts received with those listed in the Parts List
on page 8.

If any parts are missing or broken, please call Harbor Freight Tools at the number
on the cover of this manual.

Assembly

Find a safe, dry, well lighted work space to do the assembly. An elev ated work
bench will make this job much easier. You will require small wrenches and screw
driver (not included) to complete this task. Hand tools are available from Harbor
Freight Tools.

First, assemble the BBQ top.

1. Install the Top Handle (16) by placing
it in position on top of the Grill Top
(1). The threaded studs on the
handle will protrude throught the top.

2. Next, place the Lid Hanger Bracket
(17) over the threaded studs with the
hook toward the outside edge, as
shown in the picture. Place a
Washer (18) and Hex Nut (19) over
each threaded stud and tighten
securely. (Do not ov ertighten as this
might break the stud off the handle.

Next, assemble the grill bottom.

3. Place the Grill Bottom (4) upside down on the work bench. Install the Side
Handles (22) by positioning them at the predrilled holes, and passing a Side
Handle Screw (23) through a Side Handle Washer (24) through the predrilled
hole in the side of the Grill Bottom (4) and into the appropriate hole in the Side
Handle (22). Repeat this process for both screws on both handles, tighten
screws securely .

4. Take a Short Leg (6) in hand, and observe which end has a threaded slug
welded into the end of it. Press this end into a Leg Holder (5) from the curved
side in. Position the Short Leg / Leg Holder assemble against the Grill Bottom
(4) at one of the predrilled holes. Insert a Leg Screw (20) through a Leg
Washer (21), through the predrilled hole in the Grill Bottom (4) and into the
threaded slug in the end of the Short Leg (6). Finger tighten only.

SKU 91250 Page 5

5. Repeat the process with the second Short Leg (6). When assembling the
second short leg be sure that one of the Side Handles (22) is between the pair
of short legs. This will make it easier to move the BBQ once completely
assembled.

6. Take a Long Leg (7) in hand, and determine which end has the threaded slug
welded into the end of it. Press this end into a Leg Holder (5) from the curved
side in. Position the Long Leg / Leg Holder assemble against the Grill Bottom
(4) at one of the predrilled holes. Insert a Leg Screw (20) through a Leg
Washer (21), through the predrilled hole in the Grill Bottom (4) and into the
threaded slug in the end of the
Short Leg (6). Finger tighten only.
Repeat this process with the
second Long Leg (7).

7. Install the Wire Shelf (9) onto the
legs by placing its hooked ends
into the holes in each of the Long
Legs (7) as shown in the picture.
The hooks must point downward
away from the Grill Bottom (4).
The long ends of the Wire Shelf
(9) pass through the holes in the
ends of the Short Legs (6) forming
the axle for the Wheels (11). With
the Wire Shelf (9) in place , tighten all four of the Leg Scre ws (20) securely.

Next, install the wheels and caps onto the legs.

8. Place the Wheel Spacer (10) onto an axle end, then a Wheel (11) then a
Washer (12) then a Cap Nut (13). Tighten securely. Repeat this process for
the other wheel.

9. Press a Leg Cap (14) onto the end of each Long Leg (7). Be sure it is pressed
on all the wa y. Do not hammer it on, as it might break. If it is too difficult to
slide on, you may use a little dish liquid as a lubricant.

10. You may now turn the BBQ upright on a flat surface, place the Grate (3) into
the Grill Bottom (4), place the Grill (2) with the handles up into the Grill
Bottom (4) and position the Grill Top (1) on top .

NOTE: The grill is shown upside down,
as it will be during assembly.

SKU 91250 Page 6

Operation

When using the BBQ, be sure to place it on a flat, secure surface, at least 5 feet
away from any adjacent or overhanging flammable materials. Be aware of overhang­ing shrubbery or building construction, as significant heat will rise from the BBQ
when in use. Provide yourself with a water hose or bucket as an emergency
measure in case the fire gets too strong.

NOTE: Before using the BBQ for the first time, be sure to wash the Grill (2) thor­oughly with anti-bacterial soap to be sure it is clean enough to use in preparing
food. Please also wash or wipe down all other parts of the BBQ to be sure it is
clean and safe for food preparation.

1. Pour approximately 1 gallon by volume of charcoal briquettes onto the Grate
(3) in the bottom of the BBQ. Move the tab on the vent at the bottom of the
grill so the holes are completely open.

2. Spray onto the briquettes an appropriate amount of recommended lighting
fluid. Do not use gasoline or other non-recommended flammable materials.
Please follow manufacturer’s directions on the lighting fluid package.

3. Be sure that there are no children, animals or bystanders near the BBQ.
When it is safe to do so, TOSS a lighted match onto the prepared briquettes.
DO NOT lean over the briquettes when lighting as a flame is likely to quickly
shoot up from the coals, potentially causing injury.

4. W ait for the flames to die down. Then open the vents on the Grill Top (1)
completely, and place in position on top of the BBQ. NOTE: It will usually tak e
15-20 minutes for the coals to completely heat up after the initial flames
caused by the lighting fluid have died down. It is important to have both the
upper and lower vents open during this process to allow maximum oxygen to
the coals.

1 1 . Place the Ash Tray (8) into position

on the legs. With the concave side
up, place the Ash Tray (8) onto the
legs, turning it counter-clockwise
which locks it into place, as shown
in the picture. The tray can be
removed b y turning it the other way.

SKU 91250 Page 7

5. Check the coals periodically. When they hav e become thoroughly lighted (you
can observe grey areas over most or all of the coals) you can begin to cook
your food. NOTE: You can control cooking temperature by having the top on or
off, and by adjusting the vents in the top and bottom. Closing the vents will
reduce oxygen supply, and make the fire cooler. Opening the vents will
increases oxygen supply and make the coals b urn hotter. Having the top on
will reduce oxygen supply, but will hold heat in, assisting cooking of the top of
the food. Having the top off will reduce cooking to the top of the food, but the
bottom will continue to cook, based on the heat of the coals.

NOTE: When not in use, the top of the BBQ may be hung on the side of the BBQ,

using the Lid Hanger Bracket (17).

6. After removing your food and completing the cooking process, place the top
onto the BBQ, and shut completely both the top and bottom vents. This will
choke the coals of oxygen, and discourage continued burning.

WARNING: Never leav e the BBQ unattended while it is hot. K eep the BBQ in view
while you are eating, and afterwards until the coals have been safely disposed of.
Risk of fire including severe personal and property damage may result from unat­tended burning coals in a BBQ.

7. Before disposing of expended coals, be sure that they are no longer hot. Be
aware that there ma y be hot coals or ash in the ash tr a y. Using a w ater hose
at low pressure, spray water into the BBQ onto the coals. Continue this
process until you are sure that the coals are not burning, and are cold. Spray
water into the ash tray to be sure that there are no burning or hot ashes or
coals there.

8. When you are sure that the coals are no longer burning, dispose of them
properly , such as in y our garden, compost pile, or into the outdoor trash.
WARNING: Never dispose of b urning coals. Risk of fire and se vere personal or
property damage exists with improperly disposed burning coals.

Maintenance

1. After each use, scrub the Grill (2) thoroughly to remove cooking residue.

2. Thoroughly rinse out the Grill Bottom (4), Grate (3) and Ash Tray (8).

3. Store the BBQ in a dry secure place to prevent damage. Do not leave out in
the weather , as this may cause corrosion or other damage .

4. Periodically check to be sure that all fasteners are secure. Retighten if
necessary.

SKU 91250 Page 8

Parts List

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM
IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE
BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR
THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PR ODUCT. IN FACT,
THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THat ALL REPAIRS
AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK
AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT
OR REPLACEMENT PARTS THERETO , OR ARISING OUT OF HIS OR HER INSTALLA TION
OF REPLACEMENT PARTS THERETO.

NOTE: Some parts are listed and shown for illustration purposes only and are not
available individually as replacement parts.

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SKU 91250 Page 9

Assembly Drawing