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register your grill online at
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461240504 • 80001916 05-24-04
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Installation Safety Precautions WARNING • Use grill only with LP (propane) gas and the regulator/valve assembly supplied. FOR YOUR SAFETY Grill installation must conform with local codes, or in their 1. Do not store or use gasoline or other absence with National Fuel Gas Code, NFPA 54 / ANSI flammable vapors and liquids in the Z223.1 or CAN/CGA-B149.2 Propane Installation Code. vicinity of this or any other appliance. Handling and storage of LP cylinders must conform to LP Gas 2. An LP tank no
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TABLE OF CONTENTS WARRANTY For Your Safety......................................2 Manufacturer warrants to the original consumer-purchaser only that this product shall be free from defects in workmanship Grill Service Center...................................2 and materials after correct assembly and under normal and reasonable home use for the periods indicated below beginning Product Record Information ............................2 with the date of purchase. Installation Safety Precautions....
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PARTS LIST – Model No. 461240504 Key Qty Description Part # Key Qty Description Part # A 1 Lid Insert........................ 80000503 1 Side Shelf Assembly ............. 80000808 B 1 Lid End Cap - Left ................ 80000501 AA 1 Side Shelf....................... 80000060 C 1 Lid End Cap - Right ............... 80000502 BB 1 Side Shelf Panel.................. 80000518 D 1 Lid Handle ...................... 80000506 E 1 Thermometer .................... 80000096 CC 1 Cart Side w/Panel, Left....
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G PARTS DIAGRAM – Model No. 461240504 A E F C TT B M M M TT D K I NN N AA L L L BB P J H T UU Q LL Z S S S SS V R R O U MM Y X CC DD R FF QQ FF W EE RR RR FF PP FF QQ JJ GG HH II KK KK OO 461240504 5
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NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from those on your particular grill model. However, the method of assembly remains the same. ASSEMBLY – Model No. 461240504 1 First, remove door brace from rear legs. Place door Door brace brace onto front legs as shown. Tabs on brace fit inside legs. Secure brace to back of front legs using one 4.2X10mm self-tap screw (ZZ) on each side. Rear view Rear view Left front leg ZZ 2 Locking casters on front legs. Atta
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3 This step requires two people to lift and position grill head onto cart. Carefully lower the grill head onto the cart between the two braces. Align the two holes on each side of the grill head with the two holes on each brace. Make sure the regulator hose is hanging outside the cart. Align holes Regulator hose 4 Secure grill head to leg braces using four 1/4-20x3/4” screws (AAA), 7mm lock washers (BBB), and 7mm flat washers (CCC). Screws must be attached from inside of grill head into brace. D
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5 CAUTION SHARP EDGES! Wear gloves if necessary. Place side shelf over right cart legs. Lip of shelf should fit between grill bottom and leg brace. Secure shelf brackets to cart legs using one 1/4-20x3/4” screw (AAA), 7mm lock washer (BBB), and 7mm flat washer (CCC) on each bracket. AAA BBB CCC Repeat on front bracket Place sideburner shelf over left cart legs. Lip of shelf should fit between grill 6 bottom and leg brace. Secure shelf brackets to cart legs using one 1/4-20x3/4” screw (AAA), 7mm
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7 Remove the two screws and washers from the sideburner valve bracket. Place sideburner valve under front of sideburner control panel so that valve stem comes through large hole. Secure valve to panel using the two screws and washers you removed from the valve bracket. Press control knob onto valve stem. First, remove screws and washers from bracket. Sideburner valve 8 Insert sideburner into shelf, placing end of burner over sideburner valve. Valve should be in center hole of burner tube. Make s
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Front of firebox Flametamer Insert valve clip into small hole in bottom of burner, then snap other end of clip over sideburner valve. Beneath sideburner 9 shelf, attach sideburner ignitor wire to electrode. Place brass top on sideburner, then place sideburner grate onto shelf. Valve clip Sideburner ignitor wire Place flametamers (3) over burners by inserting tabs into slots in front of firebox. 10 Opposite ends of flametamers rest on pins in back of firebox. 10 461240504 Back of firebox Flamet
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11 Place cooking grates into grill bottom. Grate wires running front to back should be facing upward . . . side to side wires downward. Side-to-side wires on bottom. To assemble SwingAway, first insert 12 pivot wire into holes in side of grill lid. Pivot wire Second, insert leg wires into holes in sides of grill bottom. 461240504 11 SwingAway Leg wire
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13 Insert bottom door pin into hole in bottom shelf. Press the top door pin down, align with hole in door brace, release door pin. Press pin on door top CAUTION SHARP EDGES! Wear gloves if necessary. 14 Slide condiment baskets into brackets on back of both doors. Smaller basket on left door, larger basket on right door. 12 461240504
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15 Hang the match-lighting sticks and chains from the small hooks on the left and right side panels. 16 Slide grease tray into back of grill. Make sure drain hole is on left side 461240504 13
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17 Slide grease receptacle into rails beneath grease tray. CAUTION Failure to install receptacle on tray will cause hot grease to drip from bottom of grill with risk of fire or property damage. Grease receptacle LP tank is sold separately. Fill and leak check the tank (see Use & Care section) before attaching to grill and regulator. 18 Once tank has been filled and leak checked, place tank into tank hole in bottom shelf. Make sure tank valve is facing front of grill. Secure tank with tank scre
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VERY IMPORTANT! 19 Regulator and hose must pass UNDER hose bracket before connecting to LP tank. Read “Connecting Regulator to the LP Tank” in the Use and Care section of this manual. NOTE: Doors not shown for clarity. Regulator and hose Hose must pass UNDER Bracket hose bracket. 20 Unscrew ignitor cap and place AA battery into ignitor slot with positive end (+) facing outward. Screw ignitor cap onto ignitor. + – AA Battery 461240504 15
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LP Tank USE AND CARE The LP tank used with your grill must meet the following requirements: DANGER Use LP tanks only with these required measurements: 12" (30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.) capacity maximum. Never fill the cylinder beyond 80% full. An overfilled spare LP tank is hazardous due to possible gas LP tanks must be constructed and marked in accordance with released from the safety relief valve. specifications for LP tank of the U.S. Department of Tra
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e s i w k LP Tank Exchange Connecting Regulator To The LP Tank Many retailers that sell grills offer you the option of replacing 1. LP tank must be properly secured onto grill. (Refer to your empty LP tank through an exchange service. Use only assembly section.) those reputable exchange companies that inspect, precision fill, 2. Turn all control knobs, including sideburner, to the OFF test and certify their cylinders. Exchange your tank only for position. an OPD safety feature-equipped tank as
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Straight Leak Testing Valves, Hose and Regulator 1. Turn all grill control knobs to OFF. 2. Be sure regulator is tightly connected to LP tank. 3. Completely open LP tank valve by turning hand wheel counterclockwise. If you hear a rushing sound, turn gas off immediately. There is a major leak at the connection. Correct before proceeding. 4. Brush soapy solution onto areas circled below. Hold coupling nut and regulator as shown for proper connection to LP tank valve. 6. Turn the coupling nut clock
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Safety Tips WARNING Before opening LP tank valve, check the coupling nut for tightness. For Safe Use Of Your Grill And To Avoid Serious When grill is not in use, turn off all control knobs and LP tank Injury: valve. Do not let children operate or play near grill. Never move grill while in operation or still hot. Keep grill area clear and free from materials that burn. Use long-handled barbecue utensils and oven mitts to avoid Do not block holes in bottom or back of grill. burns and
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Burner Flame Check Remove grates and flametamers. Light burner, rotate knobs CAUTION from HI to LOW. You should see a smaller flame in LO position than seen on HI. Always check flame prior to each use. If burner does not light, turn knobs to OFF , wait 5 Perform flame check on sideburner. If only low flame is seen minutes, and try again. If the burner does not ignite with refer to "Sudden drop or low flame" in the Troubleshooting the valve open, gas will continue to flow out of the burner Sect
