THIS GRILL IS FOR
OUTDOOR USE ONLY
Failure to follow all manufacturer’s
instructions could result in serious
personal injury and/or property
damage.
WARNING
!
CAUTION
!
Some parts may contain sharp edges
– especially as noted in the manual!
Wear protective gloves if necessary.
CAUTION:
INSTALLER/ASSEMBLER:
CONSUMER:
Read and follow all safety
statements, assembly instructions,
and use and care directions before
attempting to assemble and cook.
Leave
these instructions with consumer.
Keep this manual for
future reference.
461841204
ASSEMBLY MANUAL
461841204 / 4165400 (12-22-03) - 0
Parts List - Model 461841204
Key Qty. Description Part #
A 1 Condiment Basket ............4151017
B 1 Tank Wire Support Bracket .....4151019
C 1 Wire Shelf ..................4151033
D 1 Lower Warming Rack..........4152125
E 1 Grate ......................4152741
F 1 Handle .....................4154603
G 2 Shelves ....................4154542
H 1 Upper Warming Rack..........4156449
I 2 Wheel Assemblies ............4310002
J 1 V-Bar ......................4500291
K 1 Heat Shield .................4500305
L 1 Bottom Shelf ................4503162
M 1 Panel ......................4503164
N 2 Leg Assembly................4503205
O 4 Self-tap Screw, #10x1/2 ........4080043
P 2 Valve Clip ...................4151043
Q 1 Burner/Collector Assembly......4505085
R 1 Ignitor Wire..................4153196
S 1 Ignitor ......................4153713
T 1 Valve/Hose/Regulator Assy .....4524197
Key Qty. Description Part #
U 1 Control Panel Assembly........4526138
V 1 Grill Bottom .................4580480
W 1 Grill Top ....................4580783
X 2 Control Knob ................4154470
Y 2 Leg Extender ................4154577
Z 1 Logo Plate ..................4157144
AA 1 Grease Clip .................5156607
- - 1 Hardware, Cart...............4254078
- - 2 Hardware, Shelf ..............4254050
If you have any questions or need
assistance during assembly, please
call 1-800-241-7548.
Visit us on the web at:
www.charbroil.com
Optional Assemble Hardware
Optional hex nutsWe realize some customers prefer to use tools.
have been provided for you to use.
Z
W
F
J
O
O
E
G
A
B
P
Q
K
L
R
S
U
V
T
X
I
C
M
AA
Y
N
N
G
D
H
COLUMBUS, GA
Note: Grill lid
style may vary.
Qty: 2
461841204
Items to Assemble:
2 Wheel Assemblies
2 Hitch Pins
2 Leg Extenders
Items to Assemble:
2 Leg Assemblies
1 Bottom Shelf
6 Carriage Bolts
6 Wing Nuts
Qty: 6
Qty: 6
Place Bottom Shelf and Legs as shown.
After assembling tighten all Wing Nuts.
Right Side:
Attach 2 Carriage Bolts and Wing Nuts in
front and back.
Left Side:
Place 1 Carriage Bolt
and Wing Nut in upper hole only
Items to Assemble:
1 Condiment Basket
Item to Assemble:
1 Wire Shelf
1 Panel
2 Push Pins
Qty: 2
Assemble front panel by placing
tabs into slots on Bottom Shelf.
Attach with push pins.
A
B
Place Wire Shelf in 3rd hole from top.
A
B
Attach Wheels with Hitch Pins
Items to Assemble:
1 Grill Bottom
1 Heat Shield
4 Carriage Bolts
4 Wing Nuts
2 Control Knobs
Qty. 4
Qty.4
Items to Assemble:
2 Shelves
8 Wing Screws
Qty: 8
Correct position of LP tank
and tank wire support
bracket after grill assembly
Items to Assemble:
1 Lower Warming Rack
1 Upper Warming Rack
A
B
Insert pivot wire of Lower Warming Rack into Lid.
Flex leg wires to insert into Grill bottom.
Insert pivot wire of Upper Warming Rack into lid.
Flex leg wires to insert into loops on Lower Rack.
Leg wires on both Warming Racks
must run underneath surfaces.
Legs snap into loop
B
A
Items to Assemble:
1 V-Bar
1 Grate
Push V-Bar down onto rest
in Grill Bottom
Warming Racks not shown for clarity.
See Use & Care Manual for “Match Lighting Instructions” and to
perform the Burner Flame Check” and important safety
instructions before using.
Hang grease clip from center of grill bottom.
Use an empty soup can (not included) to hang
from grease clip.
Items to Assemble:
1 Grease Clip
1 Tank Wire Support Bracket
LP tank is sold separately. Use only with an
(over-fill protection device) OPD equipped LP tank.
Fill and leak check before attaching to grill and regulator.
CAUTION
!
• Failure to install can in clip will cause hot grease
to drip from bottom of grill with risk of fire or
property damage.
• 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.
11
Back of Grill
Grease Clip
12
“R”
Right
“L”
Left
Note: On the underside of the lamp assemblies are “L” for left side
and “R” for right side. Match to letters on the handle.
Attach right and left lamp assemblies to lid with either thumbscrews
or Phillips head screws provided. Do not overtighten screws.
Overtightening will cause handle to crack.
or
or
Or
Items to Assemble:
1 Handle Assembly
1 Right Lamp Assembly
1 Left Lamp Assembly
CAUTION: To prevent a shorting condition make sure
the lamp assemblies are fully inserted into casting.
Screw
Left Lamp
Assembly
Casting
NO GAP
INCORRECT ASSEMBLY
CORRECT ASSEMBLY
L
Casting
Screw
Left Lamp
Assembly
L
9
Hinge Pin
and Hitch Pin
Items to Assemble:
1 Grill Lid
2 Hinge Pins
2 Hitch Pins
1 Logo Plate Assy
Qty: 2
Qty: 2
1
9
11
10
9
8
4
5
6
7
1
2
3
-
1
-
2
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