7
6
5
3
4
2
1
A
Leg Assembly, Left
Shelf Mounting
Bracket
A
Grill Bottom
Bracket
Tab into
small hole
Qty. 6
A
EXPLODED DIAGRAM
Some parts may be preassembled.
See parts list for cross reference.
PARTS LIST
Part appearance may differ slightly.
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
20 2 Shelf Bracket, Left Front, Right Rear . . 80000727
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
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
46 1 Temperature Gauge with Nut ........80000237
1 Hardware Pack...................80000767
1 Assembly Instructions .............80000957
1 Use & Care Manual ...............80000739
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
folding shelf
Qty. 6
A
Qty. 2
B
C
Qty. 2
Leg Assembly, Left
Hub Cap
Wheel
Tank
Support
Bracket
B
C
B
Attach the grill bottom bracket to the left leg assembly plate using two screws (A)
Attach mounting bracket using four screws (A). Place tank support bracket between
ends of legs. Insert axle bolts (B) through wheels into bracket. Secure with hitch pins (C). Snap hub caps onto wheels.
. Tab on bracket fits into small hole between
screw holes on plate. sideburner shelf
Qty. 2
D
D
D
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.
Mid Brace
G
Qty. 2
Burner Assembly
Grill Bottom
G
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
. Insert two screws (G) from inside grill bottom, through base plate,
into control panel.
DO
NOT FULLY TIGHTEN Note illustration of proper valve/burner tube engagement.
E
Qty. 4
F
Qty. 4
H
Qty. 4
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
E
H
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.
Bottom Lid Hinge
Qty. 4
A
Qty. 2
D
F
Qty. 2
G
Qty. 2
Control
Panel
Assembly
D
D
G
1
2
3
4
5
6
7
7
8
8
9
10
11
11
12
12
13
14
15
16
17
18
19
38
20
20
21
21
39
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Valve
Burner Tube
H
A
A
P
P
P
Qty. 4
Do not fully
tighten
A
Leg Assembly, Right
Folding Shelf
Mounting Bracket
A
Grill Bottom
Bracket
Tab into
small hole
Leg Assembly, Right
Leg Extender
Align tab
with
notch
C
Do not fully
tighten
G
F
F
Base Plate
36
37
THIS GRILL IS FOR
OUTDOOR USE ONLY
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.
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.
461644604
ASSEMBLY MANUAL
If you have any questions or need assistance
during assembly, please call 1-800-241-7548.
461644604 / 80000957 (02-02-04)
N
40
41
42
43
44
45
Slotted
Hole
Round
Hole
46
18
10
8
Grease Clip
Grease
Cup
Fully tighten control
panel screws now.
17
Insert grease cup into grease clip, then hang grease clip from drain hole in grill bottom.
Fully tighten control panel screws now.
• Failure to install cup in clip will cause
hot grease to drip from bottom of grill
with risk of fire or property damage.
CAUTION
Short Ignitor Wire
9
ASSEMBLY INSTRUCTIONS
461644604
HARDWARE PACK
There may be extra hardware.
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.
Insert one screw (E) into each side of grill bottom from the outside.
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
Qty. 1
J
Qty. 1
E
Qty. 2
F
Qty. 2
VapoRISER Bar
Tank
Retainer
Bracket
E
F
F
J
I
E
Rear
Shelf Bracket
Front
Shelf Bracket
Right Side Shelf
(Lighting instructions
printed on shelf)
E
Qty. 12
K
Qty. 8
L
Qty. 2
Side Shelf Grip
(Right side only)
E
K
K
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.
12
FRONT
BACK
Front
Panel
Position front panel between front legs. Insert four fasteners (M) through edges
of panel and into legs.
M
Qty. 4
M
16
Cooking
Grate
Warming
Rack
Tool Hook
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.
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
LP Gas Tank
(not included)
Tank Collar
15
C
Qty. 2
O
Qty. 2
Place top lid hinges inside bottom hinges and align
holes. Insert hinge pins (O) and secure with hitch
pins (C).
O
C
O
Qty. 20
A
Qty. 2
B
C
Qty. 4
Qty. 4
D
E
Qty. 18
F
Qty. 10
G
Qty. 5
H
Qty. 4
I
Qty. 1
J
Qty. 1
K
Qty. 8
L
Qty. 2
M
Qty. 6
N
Qty. 2
O
Qty. 2
P
Qty. 8
Handle
Handle
Logo Plate
Top Lid Hinge, Right
Top Lid Hinge, Left
Grill Lid
Qty. 4
A
Qty. 4
F
Qty. 2
N
Qty. 2
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.
A
F
N
N
P
P
P
13
FRONT
BACK
M
Qty. 2
Insert tabs on front panel extension into slot in front panel. Secure extension to
legs using two fasteners (M).
Front Panel Extension
M
Ignitor
Control Knobs
L
Long Ignitor Wire
See Use & Care manual to perform the
“Burner Flame Check” and for important
safety instructions before using.
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.
CAUTION
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.
Secure burner to shelf using one hex nut (F) on
threaded stud. Beneath shelf, attach sideburner
ignitor wire to sideburner electrode.
See illustration
below for proper tube-to-valve engagement.
G
Sideburner
Knob
Electrode
Hole
Sideburner
Electrode
Sideburner
F
Valve Cup
Proper tube-to-valve
engagement.
Burner Tube
Valve
Sideburner
Ignitor Wire
G
Qty. 1
F
Qty. 1
Sideburner
Grate
Temperature
Gauge
F
Temperature
gauge Nut
-
1
-
2
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