Harbor Freight Tools 91250 User manual

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Bar-B-Q Charcoal Grill-B-Q Charcoal Grill
-B-Q Charcoal Grill-B-Q Charcoal Grill
-B-Q Charcoal Grill
ASSEMBLY AND OPERATING INSTRUCTIONS
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit ourWeb site at http://www.harborfreight.com
Copyright © 2004 by Harbor Freight Tools®. All rights reserved. No portion of this
manual or any artwork contained herein may be reproduced in any shape or form
without the express written consent of Harbor FreightTools.
For technical questions and replacement parts, please call 1-800-444-3353
91250

SKU91250 Page 2
Specifications
SaveThis Manual
You will need the manual for the safety warnings and precautions, assembly
instructions, operating and maintenance procedures, parts list and diagram. Keep
your invoice with this manual. Write the invoice number on the inside of the front
cover. Keep the manual and invoice in a safe and dry place for future reference.
Safety Warnings and Precautions
WARNING:When using this BBQ, basic safety precautions should always be
followed to reduce the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
1. Keep assembly and operation area clean. Cluttered areas invite injuries.
2. Observe work area conditions. Do not use in damp or wet locations. Don’t
expose to rain. Keep area well lighted.
3. Keep children away. Children must never be allowed in the area when the
BBQ is in use or remains hot.
4. Store idle equipment. When not in use, BBQ must be stored in a dry
location to inhibit rust.
5. Use eye protection. Alwayswear ANSI approved impact safetygoggles
whenassemblingthis product.
6. Do not overreach. Keep proper footing and balance at all times. Do not
reach over or across BBQ when in use or hot.
7. Stay alert. Watch what you are doing, use common sense. Do not use when
youare tired.
8. Use recommended lighting fuel. Use approved barbecue lightingfuelto
ignite briquettes. Never use Gasoline or other non-recommended
flammable liquids.
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SKU91250 Page 3
9. Extinguish Briquettes when finished. Donotdump hot briquettes; afire
may result. Extinguish briquettes with water and make sure they are cold
beforedisposing ofthem properly.
10. Use the BBQ on a level surface, well away from any flammable materials.
A level surface is required for proper stability of this BBQ. Do not ignite within
5 feet of any flammable materials, such as overhanging shrubbery or awning,
draperies,buildingsetc.
11. Check for damaged parts. Before using the BBQ, any part that appears
damagedshould be carefully checked to determine thatit will work properly
andperform its intended function. Any part that is damaged must be repaired
properlyor replaced by aqualified technician prior touse.
12. Do not leave the BBQ unattended while hot. Never leave the BBQ
unattended by a qualified adult while it is hot.Severe injury, fire, or damage to
propertymay result.
13. Avoid Burns. Never move the BBQ while it is hot.Use long handled utensils
(available fromHarbor FreightTools)toavoid burns or splatters.Avoidspilled
grease into the hot briquettes, as flame up may result.
14. Replacement parts and accessories. When servicing, use only identical
replacement parts.Use of any other parts will void the warranty.Only use
accessoriesintended for usewith this tool.Approved accessories are
availablefromHarborFreightTools.
15. Do not operate tool if under the influence of alcohol or drugs. Read
warning labels on prescriptions to determine if your judgment or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.
16. Maintenance. For your safety, service and maintenance should be performed
regularlyby a qualifiedtechnician.
17. Charcoal produces carbon monoxide (CO) when it is burned. CO is a
colorless, odorless gas that can accumulate to toxic levels in closed
environments. To reduce the risk of CO poisoning:Never burn charcoal
inside of homes, vehicles, tents or campers. Charcoal should never be
used indoors, even if ventilation is provided.
Note: Charcoal produces CO fumes until the charcoal is completely
extinguished; do not store the Grill indoors with freshly used coals.
Warning:Thewarnings,cautions,andinstructions discussed in thisinstruction
manual cannot cover all possible conditions and situations that may occur. It
mustbe understood bythe operatorthatcommon senseand caution arefactors
which cannot be built into this product,but must be supplied by the operator.

SKU91250 Page 4
Unpacking
When unpacking, please compare parts received with those listed in the Parts List
onpage8.
If any parts are missing or broken, please call Harbor FreightTools at the number
onthe cover of thismanual.
Assembly
Find a safe, dry, well lighted work space to do the assembly.An elevated work
bench will make this job much easier.You will require small wrenches and screw
driver(notincluded)to complete this task. Hand toolsareavailablefrom Harbor
Freight Tools.
First,assemblethe BBQ top.
1. Install theTop Handle (16) by placing
it in position on top of the GrillTop
(1).Thethreaded studs onthe
handlewillprotrudethroughtthetop.
2. Next, place the Lid Hanger Bracket
(17)overthethreadedstuds with the
hook toward the outside edge, as
shown in the picture. Place a
Washer(18)andHexNut(19)over
eachthreadedstudand tighten
securely.(Do not overtighten as this
might break the stud off the handle.
Next, assemble the grill bottom.
3. Place the Grill Bottom (4) upside down on the work bench. Install the Side
Handles (22) by positioning them at the predrilled holes, and passing a Side
HandleScrew(23) through a SideHandleWasher (24)throughthepredrilled
hole in the side of the Grill Bottom (4) and into the appropriate hole in the Side
Handle(22). Repeat thisprocess for bothscrews on both handles, tighten
screwssecurely.
4. Takea Short Leg(6) in hand, andobservewhich end has athreaded slug
welded into the end of it. Press this end into a Leg Holder (5) from the curved
side in. Position the Short Leg / Leg Holder assemble against the Grill Bottom
(4)at one of thepredrilled holes. Insert a Leg Screw (20)through a Leg
Washer (21), through the predrilled hole in the Grill Bottom (4) and into the
threaded slug in the end of the Short Leg (6).Finger tighten only.

SKU91250 Page 5
5. Repeat the process with the second Short Leg (6). When assembling the
second short leg be sure that one of the Side Handles (22) is between the pair
of short legs. This will make it easier to move the BBQ once completely
assembled.
6. Takea LongLeg (7) in hand,and determine which end hasthe threaded slug
welded into the end of it. Press this end into a Leg Holder (5) from the curved
side in. Position the Long Leg / Leg Holder assemble against the Grill Bottom
(4)at one of thepredrilled holes. Insert a Leg Screw (20)through a Leg
Washer (21), through the predrilled hole in the Grill Bottom (4) and into the
threaded slug in the end of the
Short Leg (6).Finger tighten only.
Repeat this process with the
secondLongLeg(7).
7. Install the Wire Shelf (9) onto the
legs by placing its hooked ends
into the holes in each of the Long
Legs (7) as shown in the picture.
Thehooksmustpointdownward
away from the Grill Bottom (4).
Thelong ends of theWire Shelf
(9) pass through the holes in the
endsofthe Short Legs (6)forming
the axle for theWheels (11).With
theWire Shelf (9) in place, tighten all four of the Leg Screws (20) securely.
Next, install the wheels and caps onto the legs.
8. Place theWheel Spacer (10) onto an axle end, then aWheel (11) then a
Washer (12) then a Cap Nut (13).Tighten securely.Repeat this process for
theotherwheel.
9. Press a Leg Cap (14) onto the end of each Long Leg (7). Be sure it is pressed
on all the way.Do not hammer it on, as it might break.If it is too difficult to
slide on, you may use a little dish liquid as a lubricant.
10. You may now turn the BBQ upright on a flat surface, place the Grate (3) into
the Grill Bottom (4), place the Grill (2) with the handles up into the Grill
Bottom (4) and position the GrillTop (1) on top.
NOTE:Thegrill is shown upside down,
as it will be during assembly.

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Operation
When using the BBQ, be sure to place it on a flat, secure surface, at least 5 feet
awayfromany adjacent oroverhangingflammablematerials.Beawareof overhang-
ing shrubbery or building construction, as significant heat will rise from the BBQ
when in use. Provide yourself with a water hose or bucket as an emergency
measure in case the fire gets too strong.
NOTE: Before using the BBQ for the first time, be sure to wash the Grill (2) thor-
oughly with anti-bacterial soap to be sure it is clean enough to use in preparing
food. Please also wash or wipe down all other parts of the BBQ to be sure it is
cleanandsafefor food preparation.
1. Pourapproximately1 gallon by volumeofcharcoal briquettes onto theGrate
(3) in the bottom of the BBQ. Move the tab on the vent at the bottom of the
grill so the holes are completely open.
2. Sprayontothebriquettesanappropriateamountof recommended lighting
fluid.Donotusegasolineorothernon-recommended flammable materials.
Pleasefollowmanufacturer’sdirections on the lighting fluidpackage.
3. Be sure that there are no children, animals or bystanders near the BBQ.
When it is safe to do so, TOSS a lighted match onto the prepared briquettes.
DO NOT lean over the briquettes when lighting as a flame is likely to quickly
shoot up from the coals, potentially causing injury.
4. Wait for the flames to die down.Then open the vents on the GrillTop (1)
completely, and place in position on top of the BBQ.NOTE: It will usually take
15-20 minutes for the coals to completely heat up after the initial flames
caused by the lighting fluid have died down. It is important to have both the
upperand lower ventsopen during thisprocess to allowmaximum oxygen to
the coals.
11. Place the Ash Tray (8) into position
on the legs. With the concave side
up, place the Ash Tray (8) onto the
legs, turning it counter-clockwise
which locks it into place, as shown
in the picture. The tray can be
removed by turning it the other way.

SKU91250 Page 7
5. Check the coals periodically.When they have become thoroughly lighted (you
can observe grey areas over most or all of the coals) you can begin to cook
your food.NOTE:You can control cooking temperature by having the top on or
off, and by adjusting the vents in the top and bottom. Closing the vents will
reduce oxygen supply, and make the fire cooler.Opening the vents will
increases oxygen supply and make the coals burn hotter.Having the top on
will reduce oxygen supply, but will hold heat in, assisting cooking of the top of
the food. Having the top off will reduce cooking to the top of the food, but the
bottom will continue to cook, based on the heat of the coals.
NOTE: When not in use, the top of the BBQ may be hung on the side of the BBQ,
usingtheLid Hanger Bracket (17).
6. Afterremovingyourfood and completingthecooking process, place thetop
onto the BBQ, and shut completely both the top and bottom vents. This will
chokethecoals of oxygen,anddiscourage continued burning.
WARNING: Never leave the BBQ unattended while it is hot.Keep the BBQ in view
whileyouare eating, and afterwardsuntil the coals havebeensafely disposed of.
Riskoffireincludingsevere personal and property damage mayresultfromunat-
tended burning coals in a BBQ.
7. Before disposing of expended coals, be sure that they are no longer hot. Be
aware that there may be hot coals or ash in the ash tray.Using a water hose
at low pressure, spray water into the BBQ onto the coals. Continue this
process until you are sure that the coals are not burning, and are cold. Spray
water into the ash tray to be sure that there are no burning or hot ashes or
coalsthere.
8. When you are sure that the coals are no longer burning, dispose of them
properly, such as in your garden, compost pile, or into the outdoor trash.
WARNING: Neverdisposeofburning coals.Riskoffireandseverepersonalor
propertydamageexists with improperly disposedburningcoals.
Maintenance
1. Aftereachuse, scrub the Grill(2) thoroughly toremove cooking residue.
2. Thoroughlyrinseout the Grill Bottom (4),Grate (3) and Ash Tray (8).
3. Store the BBQ in a dry secure place to prevent damage. Do not leave out in
the weather, as this may cause corrosion or other damage.
4. Periodically check to be sure that all fasteners are secure. Retighten if
necessary.

SKU91250 Page 8
Parts List
PLEASE READTHE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM
IN THIS MANUAL AS A REFERENCETOOL ONLY. NEITHERTHE MANUFACTURER NOR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE
BUYERTHAT HE OR SHE IS QUALIFIEDTO MAKE ANY REPAIRS TO THE PRODUCT OR
THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT,
THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THat ALL REPAIRS
AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND
LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK
AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT
OR REPLACEMENT PARTSTHERETO, OR ARISING OUT OF HIS OR HER INSTALLATION
OF REPLACEMENT PARTS THERETO.
NOTE: Some parts are listed and shown for illustration purposes only and are not
available individually as replacement parts.
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SKU91250 Page 9
Assembly Drawing