assembly guide Model Number: 11601558 Propane cylinder sold separately. Estimated time required for assembly: 1 Hour PROPANE (English) 42804394 • 06/02/2010 A, B, C, Assembly: 2 ASSEMBLY GUIDE CAUTION: For your safety, before operating, Read Product Guide & Outdoor Cooking Guide provided with this grill. *SAFETY First…..Grill components may have sharp edges. Be careful when handling grill parts during assembly. We suggest that you wear a sturdy pair of leather gloves while handling the grill parts. BEFORE You begin assembly of your grill…. 1. Carefully remove all components from the carton. 2. Familiarize yourself with the components and hardware used for assembly. 3. Please note that hardware used for assembly may not be shown actual size.. 4. After removing components from the carton, split the carton open and use it as a soft, scratch-free work pad to assemble your grill. BEFORE You Grill…. 1. Read Product Guide & Outdoor Cooking Guide 2. Position Grill Safely away from walls & structures (Ref. Product Guide) 3. Pre– Heat Grill—15 minutes on 5 ,High to season grill. TIPS & Tricks…... First - Go to charbroil.com to register your grill.Take a moment to record the serial number here: _______________________________ When grilling, preheat your grill for 10 to 15 minutes with the lid down. After grilling—the Bistro can be turned on 5 , High for cleaning and burning off the grates. - Use a wire brush to brush off the grates. A light coat of oil on the grate will help prevent foods like fish and vegetables from sticking to the grate. NOTE…. Installer: Leave instructions with the grill. Consumer: Retain instructions for reference. Grill must be installed in accordance with local codes….. TOOLS REQUIRED FOR ASSEMBLY (Not Supplied) Phillips Head Screwdriver Designed for outdoor use only… Read all instructions before operating… Small Adjustable Wrench Visit www.sizzleonthegrill.com/user-forums to chat with Patio Bistro® owners just like you! 3 ASSEMBLY GUIDE Grill Parts Diagram H FF K S C A V I T CC X J G L W D DD B F N Y O E P R GG U M BB BB AA Key Qty A 1 B 1 C 1 D 1 E 1 F 1 G 1 H 1 I 1 J 1 K 1 L 1 M 2 N 1 Description Grill Lid Lower Body Heat Tent Burner Tank Retainer Bolt Ignition Harness Bezel Wind Shield Inner Reflector Towel Bar Lid Handle Control Panel Wheel Control Knob Key Qty O 1 P 1 Q 1 R 2 S 1 T 1 U 2 V 1 W 1 X. 1 Y 1 Z 1 AA 1 BB 2 HH Q Z Description Rear Leg Set Front Leg Set Grease Tray Hubcap Hose, Valve, Regulator Assembly Warming Rack Axle Heat Indicator Cooking Grate Match Holder Tank Retainer Ring Cart Base Cart Bracket Leg Cap EE Key Qty CC 1 DD 1 EE 1 FF 2 GG 1 HH 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 ... 1 Description Ignition Module Electrode Wire Ignitor Electrode Lid Bumper Match Light Hole Cover Grate Cleaning Tool Hardware Pack Assembly Manual, English Assembly Manual, Spanish, Optional Assembly Manual, French, Optional Grilling Guide Product Guide, English Product Guide, Spanish, Optional Product Guide, French, Optional NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from those on your particular model. However, the method of assembly remains the same. Visit www.sizzleonthegrill.com/user-forums to chat with Patio Bistro® owners just like you! 4 ASSEMBLY GUIDE GRILL CART Assembly Part A1– Tank Retainer Ring A2– Cart Base A3– Tank Retainer Bolt A4– Front Leg Set A5– Rear Leg Set A6– Wheels A7– Hubcap Qty 1 1 1 1 1 2 2 . 1/4x20-1/2" screw (qty 4) Wheel Retaining Clip (qty 2) 3/8-16 Nut (qty 2) Axle Bolt (qty 2) A1 A3 1/4-20 Nut Step 1 (qty 4) Assemble Tank Retainer Ring (A1) to the Cart Base (A2) by aligning studs into corresponding holes. Secure with 4 each, 1/4-20 nuts using a small adjustable wrench, not supplied. Thread the Tank Retainer Bolt (A3) into the Tank Retainer Ring(A1) A2 1/4-20 Nuts (4 each) Step 2 Attach Front Leg Set (A4) to the Cart Base (A2) using 2 1/4-20 screws. Attach Rear Leg Set (A5) to the Cart Base (A2) in the same manner, using 2 1/4-20 screws. Attach 2 Axle Bolts to the Rear Leg Set (A5), thread a 3/8-16 nut as shown and tighten securely using a small adjustable wrench. Slide a Wheel (A6) over an Axle Bolt and secure using a Wheel Retaining Clip. Repeat for other side. Position and Snap into place the Wheel Hubcaps (A7). After cart assembly, if your cart does not sit level, use these screws to adjust the cart. A5 A4 Axle Nut 3/8-16 Axle Bolt A2 1/4-20 Screws (4 each) Wheel Retaining Clip install after placing wheel on the axle. A6 Position wheel as shown Visit www.sizzleonthegrill.com/user-forums to chat with Patio Bistro® owners just like you! A7 5 ASSEMBLY GUIDE GRILL CART Assembly . Part A8– Cart Bracket A9– Leg End Cap Qty 1 2 1/4-20 Nut 1/4x20-2" screw (qty 4) (qty 4) #10x3/8" screw (qty 2) Step 3 - Carefully turn the Cart Assembly over and allow it to rest on the tops of the leg assemblies. Assemble the Cart Bracket (A8) to the Cart Assembly by by inserting 4 each 1/420x2" screws int0 into corresponding holes as shown. Allow the Cart Bracket to rest on the floor, this will help with alignment. Secure with 4 each, 1/4-20 nuts using a small adjustable wrench, not supplied. FINGER TIGHTEN ONLY AT THIS TIME. The bracket will be tightened in step B2. Be sure to install Cart Bracket (A8) on the side opposite of the ignition module bracket. Once complete -leave the cart in the upside down position. Lastly, insert the Leg End Caps (A9) into the front legs and secure with 1 each #10x3/8" screw. A8 Ignition Module Bracket #10x3/8" screws A9 1/4-20x2" screws Place the Lower Body on the carton pad upside down in preparation for the next step. Visit www.sizzleonthegrill.com/user-forums to chat with Patio Bistro® owners just like you! 6 ASSEMBLY GUIDE GRILL BODY Assembly Part Qty.. B1– Lower Body 1 B2– Wind Shield 1 B3– Grill Lid 10-24x3/8" screw (qty 3) 1 ASSEMBLY Step 1 - Attach the Lower Body (B1) to the Cart Assembly by aligning the studs on the bottom of the grill with the corresponding holes in the tops of the leg assemblies. Secure with 7 each 10-24 nuts. A Nut Driver (not supplied) will work nicely for this step. 1/4-20x3/4" Fiber Washer (qty 5) Hinge screw (qty 2) 10-24 Nut (qty 2) (qty 10) Step 3 - Attach the Wind Shield (B2) to the Lower Body (B1) by aligning the holes in the panels with the corresponding holes in the Lower Body. Secure with 3 10-24 nuts, 3 1024x3/8" Screws, and fiber washers. The Wind Shield will rest inside the Lower Body. 10-24 Nuts (3 each) Studs located on Lower Body. 1/4-20 Nut 10-24x3/8" Screws (3 each) B2 B1 B1 Fiber Washer (3 each) Step 2 - With the legs assembled to the Lower Body, tighten the 4 screws holding the Cart Bracket in place. Once complete, turn the grill over to the upright position. Step 4 - Attach the Grill Lid (B3) by aligning the hinge holes in the lid to the matching holes in the Wind Shield (B2). Insert 2 Hinge Screws into the holes and secure with 2 1/4-20 nuts and two Fiber washers from the inside of the grill. Cart Bracket 1/4-20x3/4" B3 B1 Hinge Screws (2 each) Fiber Washer (2 each) 1/4-20 Nuts (2 each) Visit www.sizzleonthegrill.com/user-forums to chat with Patio Bistro® owners just like you! GRILL FINAL Assembly 7 ASSEMBLY GUIDE Part C1 C2 C3 C4 C5 – – – – – Heat Tent Cooking Grate Warming Rack Control Knob Grease tray Qty. 1 1 1 1 1 NOTE: The Cooking Grate may have sharp edges. Be very careful when handling the Cooking Grate. You should wear gloves when handling the Cooking Grate. The cooking grate ridges should run from front to back of the grill as shown below. Be sure that the cooking grate rests squarely on the brackets spaced around the lower body. This will make for easier grate cleaning as well. Step 1 - With the Grill Lid open, place the legs of the Heat Tent (C1) into the matching impressions in the Lower Body. Next, Place the Cooking Grate (C2)into the Lower Body. The cooking grate ridges should run from front to back of the grill as shown below. Be sure that the cooking grate rests squarely on the three brackets spaced around the Lower Body. Ridges front to back C1 C2 Step 2 - Place the Warming Rack (C3) into position by first hooking the center pins into the windshield, then rotate the warming rack down into position. Next, Press the Control Knob (C4) onto the valve stem. Install the Grease Tray (C5) by sliding the tray onto the Grease Tray Rails from the rear of the grill. Note: The grease tray rests between the grease tray rail stops. See detail shown in Figure A. C3 Note: The control knob may be factory assembled Grease Tray Rails C5 C4 Fig. A Grease Tray Rail Stops Visit www.sizzleonthegrill.com/user-forums to chat with Patio Bistro® owners just like you! GRILL FINAL Assembly 8 ASSEMBLY GUIDE Part C6 – Battery C7 – Electronic Ignition Module C8 – Lid Handle Qty. 1 1 1 10-24x3/8" screw (qty 2) Fiber Washer (qty 2) NOTE: The Ignition wiring shown below will only fit into the module one way. Be sure the wires are routed away from the heat source. Do not allow the wires to rest against hot areas of the grill. Step 3 - Install the Electronic Ignition Module, Unscrew the Battery Cap and module nut from the module. Insert the module into the module bracket. Secure with the module nut. Install the Battery (C6) in the Electronic Ignition Module (C7) with the negative end first. Screw the Battery Cap back into place. Install the ignition wires as shown below. Battery Ignitor Electrode C6 + Ignitor Wire to Ignitor Electrode C7 Battery Cap Module Nut Ignition Wires from Control Panel Rear of Ignition Module shown Step 4 - Install the Lid Handle (C8) with 2 10-24x3/8" screws and 2 fiber washers as shown. Install the propane cylinder. Be sure to loosen the tank retaining bolt far enough to allow the cylinder to rest securely on the cart base. Tighten the tank retaining bolt and attach the propane regulator (not shown) when you are ready to use the grill. Cylinder valve facing RH side of grill. C8 Fiber Washer (2 each) 10-24x3/8" Screws (2 each) 20lb.Propane Cylinder Loosen Tank Retaining Bolt,install cylinder, then tighten. Congratulations! You have successfully completed the assembly of your grill. Prior to using your grill, be sure to follow the leak check instructions found in the Care and Use Guide. Visit www.sizzleonthegrill.com/user-forums to chat with Patio Bistro® owners just like you!