Page 1
E480 Barbecue
Assembly Manual
85-3040-4 (G45306) Propane
85-3041-2 (G45307) Natural Gas
1 YEAR LIMITED WARRANTY
READ AND SAVE MANUAL FOR FUTURE REFERENCE.
Assemble your grill immediately.
Missing or damaged parts claims must be submitted within 30 days of purchase date.
For product inquiries, parts, warranty and troubleshooting support,
please call 1-855-453-2150.
Manual Revision #: 12022013 PD
TM
MC
ANS Z21.58b-2012-CSA 1.6b-2012
ANS Z21.58b-2012-CSA 1.6b-2012
ANS Z21.58b-2012-CSA 1.6b-2012
Page 2
DANGER
1. If you smell Gas:
a. Shut o gas to the appliance
b. Extinguish any open ame
c. Open lid
d. If odor continues, keep away from
the appliance and immediately
call your gas supplier or your
re department
2. Requires two people to complete the
assembly process.
3. Beware of sharp edges.
WARNING
Failure to follow all of the Manufacturer’s
instructions could result in hazardous res,
explosions, property damage, or serious
personal injury or even death.
Follow all leak check procedures carefully
prior to operation of barbecue, even if grill
was dealer assembled. Do not try to light
this barbecue without reading the Lighting
Instructions section of this manual.
THIS MANUAL MUST REMAIN WITH THE PRODUCT AT ALL TIMES
CAUTION
Read and follow all safety statements,
assembly instructions, use and care
directions before attempting to assemble
and cook.
WARNING
1. Do not store or use gasoline or other
ammable liquids or vapours in the
vicinity of this or any other appliance.
2. An LP cylinder not connected for use shall
not be stored in the vicinity of this or any
other appliance.
WARNING
IN DIRECT SUN, AND IN OPERATION,
YOUR BBQ’S STAINLESS STEEL AND
PAINTED STEEL PARTS CAN BECOME
VERY HOT.
CAUTION
Sharp edges. Wear gloves when assembling
your grill.
THIS BARBECUE IS FOR OUTDOOR USE ONLY
CONTACT CALL CENTRE IF ANY PARTS ARE MISSING
1-855-453-2150
INSTALLER OR ASSEMBLER/CONSUMER
This manual should be kept with the BBQ at
all times.
HEAVY ARTICLE NEEDS 2 TO LIFT
To ORDER non-warranty replacement parts or accessories, or to register your warranty,
please visit us on the web at
www.masterchefbbqs.com
Page 3
1
TOOLS NEEDED FOR ASSEMBLY
• #2 Phillips screwdriver (long and short)
• ¼” Slotted screwdriver (long and short)
• Adjustable wrench
• Pliers
Before assembling the barbecue, read these
instructions carefully.
Assemble the barbecue on a at, clean surface.
Grill is heavy. You should have at least two people
assemble the barbecue together.
Notes: Do not fully tighten all the nuts during
this initial stage.
Caution:
Sheet metal can cause injury. Wear gloves when installing the grill.
HARDWARE PACK
¼”-20UNCX18 Screw
X 8
φ7 Washer
X 22
φ7 Lock Washer
X 18
φ5 Lock Washer
X 4
φ5 Washer
X 7
M4 Wing Nut
X 1
Control knob
X 1
Fiber Washer
X 4
Castor Pin
X 1
1 2 3
4 5 6
9
10
13
7
11
8
12
14
KEY # DESCRIPTION PART NUMBER QUANTITY
1 ¼”-20UNCX38 Screw 20120-13038-250 8
2 ¼”-20UNCX18 Screw 20120-13018-250 8
3 ¼”-20UNCX13 Screw 20120-13013-250 6
4 ¼” Nut 30220-13000-250 4
5 φ7 Lock Washer 41400-07000-250 18
6 φ7 Washer 40300-07000-250 22
7 NO.10-24UNCX10 Screw 20124-10010-250 4
8 φ5 Lock Washer 41400-05000-250 4
9 φ5 Washer 40300-05000-250 7
10 M4 Wing Nut 33301-04000-032 1
11 ST4.2X10 Tapping Screw 22500-42010-137 7
12 Fiber Washer G501-0054-9100 4
13 Control knob G453-0049-01 1
14 Castor Pin G350-0026-9000 1
15 Venturi Clip, Side Burner G405-0019-9200 1
¼”-20UNCX38 Screw
X 8
¼” Nut
X 4
NO.10-24UNCX10 Screw
X 4
ST4.2X10 Tapping Screw
X 7
¼”-20UNCX13 Screw
X 6
15
Venturi Clip, Side Burner
X 1
Page 4
2
PARTS LIST PROPANE FOR 8530404 G45306
KEY # QUANTITY DESCRIPTION PART NO.
AA 1 Top lid G453-5100-01
AB 1 Lid handle G513-0004-01
AC 1 Thermometer G432-R200-01
AD 2 Screw for top lid G453-0025-01
AE 2 Lid bumper, front G508-0063-01
AF 2 Lid bumper, rear G508-0033-01
BA 1 Burner box assembly G453-3100-01
BB 2 Brace, ame tamer G453-0004-01
BC 4 Main burner G517-7300-01
BD 3 Carryover assembly G614-0095-01
BE 4 Flame tamer G453-0020-01
BF 2 Cooking grate G453-0019-01
BG 1 Warming rack G453-0018-01
BH 1 Upper back panel G453-0010-01
BI 1 Match holder G501-0068-01
CA 1 Manifold assembly-LP G453-3300-01
CB 1 Regulator G606-0008-01
CC 4 Control knob G453-0049-01
CD 4 Bezel, control knob G501-0031-01
CE1 1 Electronic igniter assembly G409-0021-02
CE2 1 Electronic ignition button G409-0030-01
CF 1 Electrode set, main burner G515-0067-01
CG 1 Control panel G453-0050-01
CH 1 Heat shield G453-0011-01
CI 1 Grease tray G350-4400-01
CJ 1 Right track G453-0013-01
CK 1 Left track G453-0012-01
DA 1 Side burner shelf table - Left G453-0600-01
DB 1 Side burner shelf fascia - Left G453-0021-01
DC 1 Side burner lid G501-0070-01
DD 1 Side burner drip pan G515-0083-01
DE1 1 Side burner valve-LP G453-0007-01
DE2 1 Side burner metal hose G608-0039-01
DF 1 Side burner G453-3400-01
DG 1 Side burner electrode wire G515-0039-01
DH 1 Side burner cooking grate G501-0077-01
DI 1 Side shelf table - Right G453-0700-01
DJ 1 Side shelf fascia - Right G453-0022-01
EA 1 Door support rail G453-5000-01
EB 1 Cart side panel-Left G453-0300-01
EC 1 Cart side panel-Right G453-0400-01
ED 1 Bottom shelf-LP G453-0500-01
EE 2 Locking castor G350-0023-01
EF 2 Castor G350-0024-01
EG 1 Left door assembly G453-6300-01
EH 1 Right door assembly G453-6400-01
EI 2 Door handle G453-0053-01
EJ 2 Magnet assembly G501-0016-01
F1 1 Hardware pack G453-B001-03
F2 1 Assembly instructions G453-M006-01
F3 1 Safe use and care manual G453-M006-02
F4 1 Tank screw G505-0047-01
Page 5
3
EXPLODED DIAGRAM PROPANE FOR 8530404 G45306
AD
AE
BB
AF
AC
DB
EB
CI
BI
CK
CJ
EJ
EF
AA
AB
BA
CB
CA
DE1
DE2
BD
CF
BC
CG
DI
DJ
CE2
CE1
CH
EA
BH
CD
EI
EI
EE
EC
ED
EG
EH
BF
BG
BE
DC
DH
DA
DD
DF
DG
CC
HARDWARE
PAC K
TANK
SCREW
F1 F4
F2
F3
ASSEMBLY
MANUAL
SAFETY
AND CARE
MANUAL
Page 6
4
PARTS LIST NATURAL GAS FOR 8530412 G45307
KEY # QUANTITY DESCRIPTION PART NO.
AA 1 Top lid G453-5100-01
AB 1 Lid handle G513-0004-01
AC 1 Thermometer G432-R200-01
AD 2 Screw for top lid G453-0025-01
AE 2 Lid bumper, front G508-0063-01
AF 2 Lid bumper, rear G508-0033-01
BA 1 Burner box assembly G453-3100-01
BB 2 Brace, ame tamer G453-0004-01
BC 4 Main burner G517-7300-01
BD 3 Carryover assembly G614-0095-01
BE 4 Flame tamer G453-0020-01
BF 2 Cooking grate G453-0019-01
BG 1 Warming rack G453-0018-01
BH 1 Upper back panel G453-0010-01
BI 1 Match holder G501-0068-01
CA 1 Manifold assembly-NG G453-3700-01
CB 1 Natural gas hose G501-0099-01
CC 4 Control knob G453-0049-01
CD 4 Bezel, control knob G501-0031-01
CE1 1 Electronic igniter assembly G409-0021-02
CE2 1 Electronic ignition button G409-0030-01
CF 1 Electrode set, main burner G515-0067-01
CG 1 Control panel G453-0050-01
CH 1 Heat shield G453-0011-01
CI 1 Grease tray G350-4400-01
CJ 1 Right track G453-0013-01
CK 1 Left track G453-0012-01
DA 1 Side burner shelf table - Left G453-0600-01
DB 1 Side burner shelf fascia - Left G453-0021-01
DC 1 Side burner lid G501-0070-01
DD 1 Side burner drip pan G515-0083-01
DE1 1 Side burner valve-NG G453-0024-01
DE2 1 Side burner metal hose G608-0039-01
DF 1 Side burner G453-3400-01
DG 1 Side burner electrode wire G515-0039-01
DH 1 Side burner cooking grate G501-0077-01
DI 1 Side shelf table - Right G453-0700-01
DJ 1 Side shelf fascia - Right G453-0022-01
EA 1 Door support rail G453-5000-01
EB 1 Cart side panel-Left G453-0300-01
EC 1 Cart side panel-Right G453-0400-01
ED 1 Bottom shelf-NG G453-1000-01
EE 2 Locking castor G350-0023-01
EF 2 Castor G350-0024-01
EG 1 Left door assembly G453-6300-01
EH 1 Right door assembly G453-6400-01
EI 2 Door handle G453-0053-01
EJ 2 Magnet assembly G501-0016-01
F1 1 Hardware pack G453-B001-03
F2 1 Assembly instructions G453-M006-01
F3 1 Safe use and care manual G453-M006-02
Page 7
5
EXPLODED DIAGRAM NATURAL GAS FOR 8530412 G45307
AD
AE
BB
AF
AC
DB
EB
CI
BI
CK
CJ
EJ
EF
AA
AB
BA
CA
DE1
DE2
BD
CF
BC
CG
DI
DJ
CE2
CE1
CH
EA
BH
CD
EI
EI
EE
EC
ED
CB
EG
EH
BF
BG
BE
DC
DH
DA
DD
DF
DG
CC
HARDWARE
PAC K
F1
F2
F3
ASSEMBLY
MANUAL
SAFETY
AND CARE
MANUAL
Page 8
6
Separate the 2 dierent types of castors: 2
Locking Castors (EE) and 2 Regular Castors (EF).
Note: Regular Castors (EF) need to be
assembled to the front of the Bottom Shelf
(ED), and Locking Castors (EE) need to be
assembled to the back of the Bottom Shelf
(ED), as shown in image A.
Attach the Regular Castor (EF) to the front of the
Bottom Shelf (ED), and use the Pin Tool (#14) to
secure and tighten.
Repeat for remaining 3 castors (EE & EF).
1
ASSEMBLY INSTRUCTIONS
14
Upside down view
Close Up
Close Up
Front view
Ensure that the Locking Castors (EE) are rmly
locked in the “ON” position before continuing.
Assemble the Left Side Panel (EB) and the Right
Side Panel (EC), to the Bottom Shelf (ED).
2
YOU WILL NEED:
YOU WILL NEED:
14
X 1
EC
EC
EB
ED
ED
ED
EF
EE
A
B
EE
EF
Back
Front
3 5 6
X 6 X 6 X 6
Page 9
7
Attach the Upper Back Panel (BH) to both the
Left And Right Side Panels (EB & EC).
Attention: Assembly of the Upper Back Panel
(BH) will be completed in Step 7 and 10.
3
4
ASSEMBLY INSTRUCTIONS
YOU WILL NEED:
Front View
Back View
Close Up
THIS STEP REQUIRES 3 PEOPLE. DO NOT
ATTEMPT ALONE. EXTREMELY HEAVY!
Position the Top Lid Assembly and Burner Box
Assembly (A & B) onto the Cart Assembly (C), as
shown.
A
C
BH
EB
EC
EC
B
+
876
1
X 2
6
X 2
5
X 2
Page 10
8
5
6
Assemble the Door Support Rail (EA) to the Left
and Right Upper Side Panels (EB and EC), as
shown.
WARNING: This part may have sharp edges.
Wear protective gloves when assembling.
ASSEMBLY INSTRUCTIONS
Close Up
Front View
YOU WILL NEED:
EB
EA
EA
EB
EC
YOU WILL NEED:
EB
EA
BA
Attach the Match Holder (BI) to the left side panel
of the Burner Box Assembly.
BI
76
11
X 1
9
X 1
1 5 6
X 4 X 4 X 4
Page 11
9
ASSEMBLY INSTRUCTIONS
7
LEFT SIDE SHELF ASSEMBLY
TIP: Do not tighten until all hardware is in
place.
a. Mount the left side burner side shelf (DA and
DB) onto the two support brackets, located
on the left, upper side panel of the burner box
(BA).
b. Assemble the left side burner side shelf (DA
and DB ) to the upper side panel of the burner
box (BA), by positioning hardware through the
interior of the burner box (BA), as shown in
gure B.
c. Assemble the front of the left side burner side
shelf assembly (DA and DB) to the control
panel (CG), as shown in gure C.
d. Complete the left side burner side shelf
assembly (DA and DB) by connecting the side
shelf, the rear of the Burner Box side panel
(BA), and the Upper Back Panel (BH), as shown
in gure D.
YOU WILL NEED:
YOU WILL NEED:
BA
DB
DA
DA
D
A
Back, Left side view
Front, Left side view
View inside burner box
Front, left side view
YOU WILL NEED:
DA
DB
BA
B
A1
A1
B2
B2
BH
BA
2
12
X 2
X 2
4
X 2
6
X 2
A1 B2
2 5 6 11 9
X 2 X 2 X 2 X 1 X 1
C1
D1
1 5 6
X 1 X 1 X 1
DB
CG
DA
C
C1
C1
D1
Page 12
10
ASSEMBLY INSTRUCTIONS
8
9
a. Remove the hardware that is pre-assembled
to the Side Burner Valve (DE1), as shown in
gure A
Assemble the Side Burner Valve (DE1) to the
Left Side Shelf Fascia (DB), using the hardware
removed.
b. Assemble the Side Burner Control Knob (#13)
to the Side Burner Valve (DE1).
DE1
DE2
A
DB
YOU WILL NEED:
13
X 1
a. Position the Side Burner (DF) through the
opening in the Left Side Burner Drip Pan (DD).
DD
DF
A
B
DE1
DB
13
Page 13
11
b. Make sure that the Side Burner (DF) engages
the Side Burner Valve (DE1). Attach the Wing
Nut (#10) to the side burner (DF), as shown
in gure B.
e. Use the side burner Venturi clip (#15) to
connect the side burner (DF) to the side burner
valve (DE1).
c. Attach the end of the Side Burner Electrode
Wire (DG) to the underside of the Side Burner
Electrode (DF), as shown. Ensure that the wire
is pushed in rmly.
d. Position the side burner cooking grate (DH)
onto the side burner drip pan (DD).
ASSEMBLY INSTRUCTIONS
9
Left side view
15
DF
DF
DH
DD
DG
DE1
B
C
D
DF
E
YOU WILL NEED:
YOU WILL NEED:
10
15
X 1
X 1
DE1
Page 14
12
ASSEMBLY INSTRUCTIONS
10
BA
DJ
DJ
DI
BA
BH
DJ
CG
DI
DI
RIGHT SIDE SHELF ASSEMBLY
TIP: Do not tighten until all hardware is in place.
a. Mount the right side shelf (DI and DJ) onto the
two support brackets, located on the right,
upper side panel of the burner box (BA)
b. Assemble the right side shelf (DI and DJ) to
the upper side panel of the burner box (BA), by
positioning hardware through the interior of
the burner box, as shown in gure B.
c. Assemble the front of the right side shelf (DI
and DJ) to the control panel (CG), as shown in
gure C.
d. Complete the right side burner side shelf
assembly (DI and DJ) by connecting the side
shelf, the rear of the Burner Box side panel (BA),
and the Upper Back Panel (BH), as shown in
gure D.
YOU WILL NEED:
YOU WILL NEED:
YOU WILL NEED:
A
C
D
View, under right side shelf
Back, right side view
D1
C1
C1
A1 B2
Front, right side view
View inside burner box
DI
BA
DJ
B
A1
B2
A1
B2
2
12
X 2
X 2
4
X 2
6
X 2
2 5 6 11 9
X 2 X 2 X 2 X 1 X 1
C1
D1
1 5 6
X 1 X 1 X 1
Page 15
13
ASSEMBLY INSTRUCTIONS
11
ELECTRONIC IGNITION ASSEMBLY
a. Remove the Ignition Battery Cover (CE2) and
the plastic nut from the Electronic Ignition Box
(CE1).
b. Position the Electronic Ignition Box (CE1)
through the opening in the Right Side Shelf
Fascia (DJ) and secure using the plastic nut.
c. Insert one “AA” battery into the battery
compartment (CE1) with the positive end
facing outward, as shown. Secure using the
ignition button cover (CE2).
* Battery not included.
d. Insert the Electrode Set, Main Burner Wire (CF)
and the Side Burner Electronic Wire (DG) into
the Electronic Ignition Assembly (CE1)
as shown. Ensure that the wires are pushed
in rmly.
Note: Both wire connectors are the same.
Underneath right side shelf
Underneath right side shelf
Underneath right side shelf
DJ
CF
DJ
Battery
Plastic Nut
CE1
CE1
CE1
DG
DJ
CE2
+
-
Page 16
14
ASSEMBLY INSTRUCTIONS
12
EA
EA
CH
CH
BH
BH
CH
CH
Assemble the Heat Shield (CH) to the bottom of
the Door Support Rail (EA) and the Upper back
panel (BH), as shown in gure A and B.
YOU WILL NEED:
11
X 2
Front view
Back view
Close up
Close up
B
A
Page 17
15
ASSEMBLY INSTRUCTIONS
CK
CJ
EA
EB EC
CI
BH
a. Assemble the Right and Left Tracks (CJ and CK)
for the Grease Tray (CI), as shown in gure A-C.
b. Insert the Grease Tray (CI) into the opening of
the Upper Back Panel (BH).
YOU WILL NEED:
11
X 2
13
Close up, front
Close up, back
Back view
A
B
C
D
CJ
CJ
CK
CK
CH
Page 18
16
ASSEMBLY INSTRUCTIONS
14
Assemble the Door Handle (EI) to the Left and
Right Door Assembly (EG and EH).
Left door handle
Right door handle
YOU WILL NEED:
YOU WILL NEED:
EI
EH
7
7
8
8
9
9
X 2
X 2
X 2
X 2
X 2
X 2
Page 19
17
a. Assemble the right door assembly (EH),
to the bottom shelf (ED) by inserting the xed
pin (bottom of door) into the hole provided
(gure B).
b. Assemble the top of the door assembly (EH) to
the door support rail (EA), by pressing in the
door support pin and aligning with the hole
located on the top right corner of the door
(gure C).
TIP: Use a paint scraper to press-in the support
pin, while the second person aligns the door.
The support pin will lock into position when the
door is assembled correctly.
c. Repeat steps a, and b for the left door assembly
(EG).
EC
ED
ED
EH
EA
EA
EH
EH
15
ASSEMBLY INSTRUCTIONS
Close up, bottom of door
Close up, top of door
A
C
B
Page 20
18
ASSEMBLY INSTRUCTIONS
a. Position the Flame Tamer support braces
(BB) over the Burner Box support pins (BA) as
shown.
b. Position the Flame Tamers (BE) into the Burner
Box (BA).
16
BA
BB
Close up
BE
BE
BB
BE
Page 21
19
ASSEMBLY INSTRUCTIONS
Insert the two small positioning rods of the
warming rack (BG) into the rear panel of the
burner box (BA).
17
18
BG
BA
Place the cooking grates (BF) into the burner box
(BA).
BF
Page 22
20
ASSEMBLY INSTRUCTIONS
19
FOR PROPANE MODEL ONLY
FOR NATURAL GAS MODEL,
FOLLOW STEP 19.
a. Position the 20 lb propane tank onto the
Bottom Shelf (ED), and secure using the bolt
(already attached).
FOR NATURAL GAS MODEL ONLY
Attach the Natural Gas Hose (CB) to the Side
Burner Valve (DE1) as shown.
ATTENTION
In order to complete installation of your Natural
Gas BBQ a 1/2” or 3/8” adapter may be required
to connect your BBQ’s Natural Gas hose to your
home gas supply. Contact your Natural Gas
supplier to purchase the necessary part.
b. Attach the Regulator coupling nut (CB) to the
LP cylinder valve.
DE1
20
ATTENTION
FOR YOUR SAFETY, DO NOT ATTEMPT TO LIGHT
THIS BBQ UNTIL YOU HAVE REVIEWED PAGES
4-8 OF THE MASTER CHEF® SAFETY & CARE
MANUAL.
ALL SAFETY AND LEAK TESTS MUST BE
PERFORMED BY THE END USER, PRIOR TO
LIGHTING THIS BBQ.
ATTENTION
DO NOT STORE EXTRA PROPANE TANKS WITHIN
BBQ CART.
ATTENTION
FOR YOUR SAFETY, DO NOT ATTEMPT TO LIGHT
THIS BBQ UNTIL YOU HAVE REVIEWED PAGES
4-8 OF THE MASTER CHEF® SAFETY & CARE
MANUAL.
ALL SAFETY AND LEAK TESTS MUST BE
PERFORMED BY THE END USER, PRIOR TO
LIGHTING THIS BBQ.
CB
ED
CB
F4
ED
A
B
Page 23
21
Visit www.masterchefbbqs.com
to complete product registration
Master Chef® Customer Service
1-855-453-2150
Trileaf Distributions Trifeuil
Toronto, Ontario M4S 2B8
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