T440 Barbecue
Assembly Manual
85-3004-2 (G45118) Propane
85-3005-0 (G45119) Natural Gas
1 YEAR LIMITED WARRANTY
READ AND SAVE MANUAL FOR FUTURE REFERENCE.
If pre-assembled, leave this manual with unit for
consumer’s future reference.
For product inquiries, parts, warranty and
troubleshooting support, please call 1-877-707-5463.
Manual Revision #: 30082011 PD
HARDWARE PACK
TOOLS NEEDED FOR ASSEMBLY
KEY # 1
2
3
4
5
6
7
8
9
10
11
• #2 Phillips screwdriver (long and short)
• ¼” Slotted screwdriver (long and short)
• Adjustable wrench
• Pliers
Before assembling the barbecue, read these
instructions carefully.
H E AV Y A R T I C L E N E E D S 2 TO L I F T
THIS MANUAL MUST REMAIN WITH THE PRODUCT AT ALL TIMES
To ORDER non-warranty replacement parts or accessories, or to register your warranty,
please visit us on the web at
www.masterchefbbqs.com
CAUTION
DANGER
Sharp edges. Wear gloves when assembling
your grill.
Read and follow all safety statements,
assembly instructions, use and care
directions before attempting to assemble
and cook.
1. If you smell Gas:
a. Shut off gas to the appliance
b. Extinguish any open flame
c. Open lid
d. If odor continues, keep away from
the appliance and immediately
call your gas supplier or your
fire department
INSTALLER OR ASSEMBLER/CONSUMER
2. Requires two people to complete the
assembly process.
CAUTION
This manual should be kept with the BBQ at
all times.
3. Beware of sharp edges.
Assemble the barbecue on a flat, clean surface.
Grill is heavy. You should have at least two people
assemble the barbecue together.
Failure to follow all of the Manufacturer’s
instructions could result in hazardous fires,
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.
1. Do not store or use gasoline or other
flammable 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.
PART NUMBER QUANTITY
20120-13013-036 10
G306-0025-9084
1
31220-13000-036
8
22500-42010-136
14
40300-07000-036
6
G431-0018-9000
10
G305-0024-9088
2
G306-0005-9088
1
41400-07000-206
6
40300-08000-036
1
20102-13018-036
4
Notes: Do not fully tighten all the nuts during
this initial stage.
Caution:
Sheet metal can cause injury. Wear gloves when installing the grill.
1
2
3
¼” x 13mm Screw
X 10
4
5
6
9
Wheel Spacer
X2
10
Hitch Pin
X1
11
Washer (Wheel)
X1
Ø7 Fiber Washer
X 10
Ø7Flat Washer
X6
8
7
¼” - 20UNC Nut
X8
Wing Screw
X1
#8X3/8” Self Tapping Screw
X 14
WARNING
WARNING
DESCRIPTION 1/4” x 13mm Screw
Wing Screw 1/4”-20UNC Nut #8X3/8” Self Tapping Screw
Ø7Flat Washer Ø7 Fiber Washer Wheel Spacer
Hitch Pin
Ø7Lock Washer Washer (Wheel) 1/4” - 20UNCX18 Screw
1/4” - 20UNCX18 Screw
X4
T H I S B A R B E C U E I S F O R O U T D O O R U S E O N LY
CONTAC T C ALL CE N T R E IF ANY PARTS AR E M IS S IN G
1-877-707-5463
1
Ø7Lock Washer
X6
PARTS LIST (PROPANE) FOR 85-3004-2 (G45118)
KEY #
QUANTITY DESCRIPTION EXPLODED DIAGRAM (PROPANE) FOR 85-3004-2 (G45118)
PART NO.
AA
1
Top Lid assembly
G451-3000-01
AB
1
Thermometer and Bezel G451-0008-01
AC
1
Top Lid Handle
G413-0001-01
AD
2
Lid Bumbers- Back G303-0038-01
AE
2
Lid Bumbers- Front
G430-00B8-01
AF
2
Screws for Lid G430-0024-01
BA
1
Burner Box Assembly G451-0200-01
BB3 Burner
G432-B600-01
BC
1
Electrode Set, main burners
G501-0010-01
BD
2
Burner brace assembly
G432-0078-01
BE
3
Flame Tamers
G430-0005-01
BF
3
Cooking Grates
G451-1200-01
BG
1
Warming Rack G430-0003-01
CA
1
Control Panel G451-J001-01
CB
1
Manifold Assembly G451-J100-01
CC1 Regulator
G402-0069-01
CD
3
Bezel, Control Knob
G430-0027-02
CE
3
Control Knob
G432-0090-01
CF1
1
Electronic Igntion Assembly
G409-0021-A1
CF2
1
Electronic Ignition Button
G308-0025-01
CG
1
Grease Cup Hook
G305-0043-01
CH
1
Grease Cup
G430-0033-02
CI
1
Heat Shield
G451-6201-01
DA
1
Cart side panel, right
G451-0500-02
DB
1
Cart side panel, left
G451-0400-02
DC
1
Back brace
G431-0031-02
DD
1
Front panel G451-0005-02
DE
2
End Caps
G431-0004-01
DF
1
Match Holder
G401-0079-01
DG
2
Wheel G210-0018-02
DH
1
Wheel Axle
G430-0007-01
EA
1
Side Shelf table (right) G430-1500-A1
EB 1
Side shelf fascia(right) G451-0003-01S
EC 1
Side Shelf table (left) G430-2100-02
ED
1
Side shelf fasica (left)
G451-0007-01
EE
1
Tank Exclusion G430-5402-01
EF
1
Tank retainer clip
G306-0020-01
F1
1
Hardware Pack G451-B004-01
F2
1
Assembly Instructions
G451-M018-01
F3
1
Safe Use and Care Manual G207-M015-02
AA
AD
CB
AB
CC
BG
CI
AE
AF
AC
BF
BE
DD
BA
BB
BD
EC
ED
EB
CD
CE
BC
EF
CF1
DF
CG
CF2
CH
EE
DB
DA
DC
DG
DE
F2
F3
ASSEMBLY
MANUAL
SAFETY
AND CARE
MANUAL
DH
F1
HARDWARE
PACK
2
EA
CA
3
PARTS LIST (NATURAL GAS) FOR 85-3005-0 (G45119)
KEY #
QUANTITY DESCRIPTION PART NO.
AA
1
Top lid assembly
G451-3000-01
AB1 Thermometer
G451-0008-01
AC
1
Top lid handle
G413-0001-01
AD
2
Lid bumbers- back G303-0038-01
AE
2
Lid bumbers- front
G430-00B8-01
AF
2
Screws for lid G430-0024-01
BA
1
Burner box assembly G451-0200-01
BB3 Burner
G432-B600-01
BC
1
Electrode set, main burners
G501-0010-01
BD
2
Burner brace assembly
G432-0078-01
BE
3
Flame tamers
G430-0005-01
BF
3
Cooking grates
G451-1200-01
BG
1
Warming rack G430-0003-01
CA
1
Control panel G451-J001-01
CB
1
Manifold assembly G451-J400-01
CC
1
Natural gas hose
G501-0099-01
CD
3
Bezel, control knob
G430-0027-02
CE
3
Control knob
G432-0090-01
CF1
1
Electronic igntion assembly
G409-0021-A1
CF2
1
Electronic ignition button
G308-0025-01
CG
1
Grease cup hook
G305-0043-01
CH
1
Grease cup
G430-0033-02
CI
1
Heat Shield
G451-6201-01
DA
1
Cart side panel, right
G451-0500-02
DB
1
Cart side panel, left
G430-1000-02
DC
1
Back brace
G431-0031-02
DD
1
Front panel G451-0005-02
DE
2
End caps
G431-0004-01
DF
1
Match holder
G401-0079-01
DG
2
Wheel G210-0018-02
DH
1
Wheel axle
G430-0007-01
EA
1
Side shelf table (right) G430-1500-A1
EB 1
Side shelf fascia(right) G451-0003-01S
EC 1
Side shelf table (left) G430-2100-02
ED
1
Side shelf fasica (left)
G451-0007-01
F1
1
Hardware pack G451-B004-01
F2
1
Assembly instructions
G451-M018-01
F3
1
Safe Use and Care Manual G207-M015-02
EXPLODED DIAGRAM (NATURAL GAS) FOR 85-3005-0 (G45119)
AA
AD
CB
AB
AE
BG
CI
AF
BF
CC
AC
BE
DD
BA
BB
BD
EC
CA
EB
CD
CE
BC
CF1
DF
CG
CF2
CH
DB
DA
DC
DG
DE
DH
F1
HARDWARE
PACK
4
EA
ED
5
F2
F3
ASSEMBLY
MANUAL
SAFETY
AND CARE
MANUAL
ASSEMBLY INSTRUCTIONS
ASSEMBLY INSTRUCTIONS
1
PROPANE MODEL ONLY
Note: You will need two people for this step.
3
DG
8
DG
DH
Assemble the tank exclusion (EE) to the left and
right cart side panels (DA, DB), as shown.
DB
Note: Turn Cart assembly upside down.
10
7
7
Insert wheel axle assembly (DH) through wheel
axle hole in the front and rear, of the left cart
side panel (DB), as shown.
Note: The left cart side panel (DB) will have
large holes on the end of the legs for assembling the wheel axle (DH).
DA
EE
a. Place wheel (DG) and wheel spacer (#7) onto
wheel axle (DH). “Cone” side of wheel should
be against cart side panel, as shown in figure B.
A
To complete wheel assembly, position the
wheel spacer (#7), wheel (DG), wheel washer
(#10) and hitch pin (#8), onto wheel axle (DH),
as shown.
Front View
YOU WILL NEED:
67
710
X2
X1
8
8
DA
B
X1
Close up
EE
2
DA
Note: Turn Cart assembly over. Front panel
should be facing upward.
Assemble the back brace (DC) to the rear, left
and right cart side panels (DA, DB), as shown.
DB
DC
4
DA
EE
Assemble the front panel (DD) to the left and
right cart side panels (DA and DB), as shown.
Ensure that the slots on the tank exclusion (EE)
align with the slots on the front panel (DD).
DB
NATURAL GAS MODEL WILL NOT
HAVE WIRE-TANK EXCLUSION (EE)
SHOWN IN IMAGE.
YOU WILL NEED:
4
Back side down
YOU WILL NEED:
DD
4
X4
Front side down
X6
6
7
ASSEMBLY INSTRUCTIONS
5
A
+
ASSEMBLY INSTRUCTIONS
Note: Stand cart assembly upright. TWO
PEOPLE required for this step. Ensure that
the regulator hose (Propane models only) is
hanging outside of cart.
B
7
RIGHT SIDE SHELF ASSEMBLY
a. Insert the right side shelf assembly hooks into
the grooves located on the right side of the
burner box assembly (BA).
Position the lid and burner box assembly (A&B),
onto the cart assembly (C), and assemble.
EA
YOU WILL NEED:
EB
11
9
5
X4
X4
X4
C
Front, right side view
b. Affix the right side shelf table (EA) to the
burner box assembly (BA).
A1
BA
YOU WILL NEED:
B2
A1
A1
1
6
3
X4
X4
X4
Back view
6
Assemble the top lid handle (AC) to the top lid
assembly (AA).
AC
EA
AA
B2
YOU WILL NEED:
6
5
9
1
X2
X2
X2
X2
B2
BA
View, under right side shelf
c. Affix the right side shelf fascia (EB) to the
control panel (CA).
Securely tighten all hardware.
EA
YOU WILL NEED:
EB
4
CA
X2
View, under right side shelf
8
9
ASSEMBLY INSTRUCTIONS
ASSEMBLY INSTRUCTIONS
8
LEFT SIDE SHELF ASSEMBLY
a. Insert the left side shelf assembly hooks (EC
and ED) into the grooves located on the left
side of the burner box assembly (BA).
9
PROPANE MODEL ONLY
Insert and fasten the tank retainer clip (EF) into
the tank retainer bracket, located at the top,
center of the left cart side panel (DB).
EF
EC
ED
Back view
YOU WILL NEED:
2
Front, left side view
b. Affix the left side shelf table (EC) to the burner
box assembly (BA).
EC
B2
EF
X1
YOU WILL NEED:
B2
A1
B2
View, under left side shelf
1
6
3
X4
X4
X4
10
BA
Place the flame tamers (BE) into the burner box.
BE
A1
A1
Back view
c. Affix the left side shelf fascia (ED) to the
control panel (CA).
Securely tighten all hardware.
ED
YOU WILL NEED:
4
CA
X2
View, under left side shelf
10
11
ASSEMBLY INSTRUCTIONS
ASSEMBLY INSTRUCTIONS
11
Place the cooking grates (BF) into the burner box.
13
Hang the grease cup hook (CG) from the bottom
of the burner box (BA), and place grease cup (CH)
into position.
PROPANE MODEL SHOWN
CG
BF
CAUTION
Failure to assemble grease cup hook and grease
cup will cause hot grease to drip from the
bottom of the BBQ burner box, with the risk of
fire, property damage, or personal injury.
CH
Back view
CG
CH
12
Stationary Wire
BG
Pivot Legs
To assemble the warming rack (BG), insert the
stationary wire into the holes on the sides of the
lid. Insert warming rack pivot legs into the holes
on the inside of the burner box assembly, as
shown.
14
PROPANE MODEL ONLY
FOR NATURAL GAS MODEL,
FOLLOW STEP 15
EF
a. Propane tank collar must face to the front of
the BBQ. Loosen the wing nut from the tank
retainer clip (EF). Set bottom of the tank into
notches located on the bottom of the left cart
side panel (DB). Position tank retainer clip (EF)
onto tank collar and tighten wing nut.
ATTENTION: LP Cylinder is sold separately.
Use only LP tanks that are equipped with an
OPD (Overfill protection device). Fill and Leak
check before attaching to the BBQ hose and
regulator. See Safe Use and Care Manual, leak
test procedure for more information
DB
Left side view
CAUTION
Cylinder valve must face to the front of cart
once the tank is attached.
Failure to install cylinder correctly may allow
gas hose to be damaged in operation, resulting
in fire.
WARNING
Always keep LP cylinder in upright position
during use, transport and storage.
12
13
ASSEMBLY INSTRUCTIONS
15
NATURAL GAS MODELS ONLY
Attach the natural gas hose (CC) to the manifold
(CB), as shown.
CB
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.
CC
Left side view
16
Electronic ignition battery not included.
Unscrew the electronic ignition button (CF2) and
insert one AA battery into the electronic ignition
battery compartment (CF1), with the positive
end facing outward.
CF2
-
+
14