ROYAL OAK C1809A User manual

ASSEMBLY INSTRUCTIONS
READ INSTRUCTIONS CAREFULLY BEFORE ASSEMBLY.
RETAIN THIS MANUAL FOR FUTURE REFERENCE.
HEAVY DUTY
CHARCOAL
GRILL/SMOKER
Model # C1809A
Product Code # 230-940-431
HEAVY DUTY
ADD-ON FIREBOX
(OPTIONAL – SOLD SEPARATELY)
Model # C1809B
Product Code # 230-941-433

2
SAFETY WARNINGS
Before assembling or using your new grill, carefully read the instruction manual – including all
safety warnings! Failure to follow safety warnings could result in death, serious bodily injury,
and/or property loss.
ASSEMBLY
•Check the box and make sure you have all parts listed. If you have parts missing or damaged, please contact
Customer Service for assistance at [phone], 24 hours a day / 7 days a week.
•Use caution during assembly or operation of grill.
•Use caution when reaching into or under grill.
•When moving or lifting grill, use caution to avoid back strains or injuries. If necessary, use two people to
move grill.
•Do not attempt to operate grill until it is fully assembled. Please properly dispose of all packaging materials.
•Remove all labels before using grill.
PLACEMENT
•OUTDOOR USE ONLY! Place in a well-ventilated area. Do not use grill indoors or in an area that is enclosed
or not well ventilated.
•HOUSEHOLD USE ONLY! Do not operate or use grill for any other purpose than its intended use.
•Never use grill on a wooden surface or other combustible surfaces. Use grill only on a hard, stable surface
that can support the grill’s weight.
•Allow 10 feet of clearance between grill and any combustible materials when in use, or after use while still
hot.
•Keep grill away from gasoline and/or other flammable liquids, flammable gases, flammable vapors, or areas
where these may be present. Do not store or use grill in these areas.
•In windy conditions, place in an outdoor area that is sheltered from the wind.
•Keep out of reach of children or pets.
•When moving or lifting grill, use caution to avoid back strains or injuries. If necessary, use two people to
move grill.
•Do not try to move or reposition grill while it is in use or still hot.
LIGHTING A FIRE
•WARNING! DO NOT USE GASOLINE, KEROSENE, OR ALCOHOL TO LIGHT CHARCOAL! Using any of these
(or similar) products may result in a flare up, flash fire, or explosion. Death or severe bodily injury could
result.
•If using lighter fluid or instant light charcoal to start fire, leave the lid open until charcoal is ashed over,
flames have died down, and lighter fluid has burned off completely. Closing the lid too soon could cause
fumes from the lighter fluid to accumulate inside the grill. This may result in a flare up, flash fire, or explosion
when the lid is opened.

3
LIGHTING A FIRE (cont.)
•Do not add lighter fluid to warm or hot coals. This may result in a flare up, flash fire, or explosion.
•Do not add instant light charcoal to an existing fire. This may result in a flare up, flash fire, or explosion.
•WARNING! If smoker catches fire, use an ABC fire extinguisher to put out fire. Never attempt to extinguish a
grease fire with water or other liquids!
GRILL USAGE AND OPERATION
•WARNING! Grill is very hot during and after use. Do not touch grill surfaces with unprotected skin. Always
wear flame-retardant insulated mitts when grill is in use.
•WARNING! Do not wear loose clothing when using grill and keep hair away from grill.
•WARNING! Do not attempt to move grill while in operation or still hot.
•WARNING! Never allow children to play near grill during operation or while still hot. Never allow children to
operate grill. Keep pets away from grill.
•Lid handles may be very hot – always use flame-retardant insulated mitts when raising or lowering lids. Use
caution when opening lids, and push them back to their fully opened position. If lids are left partially opened,
they may fall closed suddenly causing bodily injury.
•Do not lean on or place more than 10 pounds on the shelves.
•WARNING! If grill catches fire, use an ABC fire extinguisher to put out fire. Never attempt to extinguish a
grease fire with water or other liquids!
•When fresh air comes in contact with flame, a flare up can result – use caution when opening lids. Maintain a
safe distance from steam and flame.
•Using flame-retardant insulated mitts, close lids and dampers to extinguish flames.
•To prolong grill finish and metal life, do not exceed a grill temperature of 400°F, and do not let burning
charcoal or wood come in contact with the walls of the grill.
ASH DISPOSAL AND CLEAN UP
•To prolong the life of your grill, properly clean after each use.
•Do not leave hot grill or hot coals and ashes unattended.
•Do not remove coals and ashes until they have completely cooled.
•Using flame-retardant insulated mitts – after coals and ashes have completely cooled – empty ashes into a
metal container. Douse with water before disposal. Keep container a safe distance from combustible
materials.
•Wet the surface beneath and around the grill to extinguish any coals or ashes that may have fallen out.
•To prevent excessive rust: clean grill after each use, apply a light coat of cooking oil, cover, and store in a
dry place.

PARTS LIST
PART
NUMBER DESCRIPTION PICTURE OF PART QUANTITY
1 MAIN BODY ASSEMBLY 1 PC
2 RIGHT LEG 2 PC
3 LEFT LEG 2 PC
4 BOTTOM SHELF 1 PC
5 WHEEL AXLE 1 PC
6 WHEEL 2 PC
7 SMOKE STACK ASSEMBLY 1 PC
8 FRONT SHELF 1 PC
9 FRONT SHELF SUPPORT 2 PC
4

5
10 SIDE HANDLE 1 PC
11 SIDE DOOR 1 PC
12 LID HANDLE 1 PC
13 PORCELAIN COATED
COOKING GRATE
3 PC
14 CHARCOAL GRATE
3 PC
15 HEAT INDICATOR 1 PC
16 DRIP CUP HOLDER 1 PC
17 LATCH RECEIVER 1 PC
18 HINGE 1 PC
19 MAIN BODY LID
1 PC

6
HARDWARE LIST
HARDWARE
LETTER DESCRIPTION PICTURE OF HARDWARE QUANTITY
A SCREW 35 PC
B NUT 26 PC
(2 pre-installed)
C WHEEL AXLE
NUT
2 PC
D WASHER
4 PC
E HINGE PIN
SCREW
2 PC
(pre-installed)

7
ASSEMBLY INSTRUCTIONS
Read assembly instructions before attempting to assemble grill. The estimated assembly time is 45 minutes. We
recommend that two people assemble this grill. Separate and identify all parts and hardware. You will need a
Phillips head screwdriver, an adjustable wrench, and a pair of pliers. Check the parts and hardware according to the
number (for parts) and letter (for hardware) from pages 4 - 6. We recommend using the bottom of the corrugated box
as an assembly pad. Be sure to assemble grill on a non-abrasive surface to avoid scratching the paint. Be sure to
remove any labels that are on the grill before attempting to use.
STEP 1: Unscrew “Hardware E” (Hinge Pin Screws) from “Part 19” (Main Body Lid) and slide Lid off of “Part 1” (Main
Body Assembly) as shown. Set Main Body Lid aside in a safe place.
STEP 2: Carefully stand “Part 1” (Main Body Assembly) on its left end (the end with the hole for the Smoke Stack).
Using 4 pieces each of “Hardware A” (Screw) and “Hardware B” (Nut), attach 1 piece of “Part 2” (Right Leg) to the
upper left set of mounting holes in the Main Body Assembly. Make sure when attaching leg, that the small hole for the
Bottom Shelf side tab is pointed in toward the center.
19
19 E
1
1
Internal view
A
A
B
A
2
1

8
STEP 3: Using 4 pieces each of “Hardware A” (Screw) and “Hardware B” (Nut), attach 1 piece of “Part 3” (Left Leg)
to the lower left set of mounting holes in “Part 1” (Main Body Assembly). Make sure when attaching leg, that the
small hole for the Bottom Shelf side tab is pointed in toward the center.
A
1
A
3
A
A
A
B
STEP 4: Attach “Part 4” (Bottom Shelf) to “Part 2” (Right Leg) and “Part 3” (Left Leg) by inserting the side tabs into
the holes in the side of each Leg.
2
4
3

9
STEP 5: Take 1 piece of “Part 2” (Right Leg) and attach to “Part 4” (Bottom Shelf) by inserting side tab into the hole
in the side of the Leg. Using 4 pieces each of “Hardware A” (Screw) and “Hardware B” (Nut), attach Leg to the upper
right set of mounting holes in “Part 1” (Main Body Assembly).
A
2
STEP 6: Take 1 piece of “Part 3” (Left Leg) and attach to “Part 4” (Bottom Shelf) by inserting side tab into the hole in
the side of the Leg. Using 4 pieces each of “Hardware A” (Screw) and “Hardware B” (Nut), attach Leg to the lower
right set of mounting holes in “Part 1” (Main Body Assembly).
4
3
2
3
4
B
2
2
4 4
A
3
B
3

10
STEP 7: Slide “Part 5” (Wheel Axle) through the holes in both Right Legs.
2 2
5
5
STEP 8: Slide both pieces of “Part 6” (Wheel) onto the ends of “Part 5” (Wheel Axle). Make sure that the side of the
wheel that has the longer stub faces inward towards the leg. Tighten both pieces of “Hardware C” (Wheel Axle Nut)
onto the Wheel Axle, locking the Wheels in place. Use a pair of pliers to grip the center of the Wheel Axle, while
tightening the Wheel Nuts with an adjustable wrench.
HINT: Wrap a piece of cloth or a paper towel around the wheel axle to help keep the axle’s paint from being scratched
while gripping with pliers.
2 5
C
6

11
STEP 9: Turn grill upright onto its legs. Using 4 pieces each of “Hardware A” (Screw) and “Hardware B” (Nut),
attach “Part 7” (Smoke Stack Assembly) to Main Body as shown below.
STEP 10: Thread “Part 16” (Drip Cup Holder) through drip hole in bottom of Main Body.
16
A
B
A 7
A
B
B

12
STEP 11: Using 2 pieces of “Hardware A” (Screw), attach “Part 8” (Front Shelf) to the Main Body using the holes in
the front of the Main Body as shown below. Then using 4 pieces of “Hardware A” (Screw), attach the 2 pieces of “Part
9” (Front Shelf Support) to both the Front Shelf and the Main Body as shown below.
A A
9
8
STEP 12: Using 4 pieces each of “Hardware A” (Screw), “Hardware B” (Nut) and “Hardware D” (Washer), attach
“Part 10” (Side Handle) to Main Body as shown below.
A
D B

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IF INSTALLING OPTIONAL HEAVY-DUTY ADD-ON FIREBOX C1809B
(SOLD SEPARATELY) – SKIP TO PAGE 14
STEP 13: Using 1 piece of “Hardware A” (Screw), attach “Part 17” (Latch Receiver) to Main Body. Using 2 pieces of
“Hardware A” (Screw), attach “Part 18” (Hinge) to Main Body.
18
1
7
STEP 14: Slide the hinge pins of “Part 11” (Side Door) into the Hinge and use latch to open and close Side Door for
ash cleanout.

14
STEP 15: Insert all 3 pieces of “Part 14” (Charcoal Grates) and then all 3 pieces of “Part 13” (Porcelain Coated
Cooking Grates) into grill. To help distinguish the grates, the Porcelain Coated Cooking Grates have a glossy black
finish.
STEP 16: Slide “Part 19” (Main Body Lid) back onto Main Body as shown. Using 2 pieces of “Hardware E” (Hinge
Pin Screws), secure Lid to Main Body.

15
STEP 17: Using 2 pieces of “Hardware B” (Nut), attach “Part 15” (Heat Indicator) to the Lid. Using 2 pieces of
“Hardware A” (Screw), attach “Part 12” (Lid Handle) to the Lid.
Assembly of Royal Oak Heavy Duty Smoker/Grill is now complete.
BE SURE TO REMOVE ANY LABELS FROM GRILL BEFORE USE!
PROCEED TO PAGE 16
FOR INSTRUCTIONS
REGARDING THE
INSTALLATION OF THE
OPTIONAL HEAVY DUTY
ADD-ON FIREBOX C1809B
(SOLD SEPARATELY)

16
INSTALLING THE OPTIONAL HEAVY-DUTY
ADD-ON FIREBOX C1809B (SOLD SEPARATELY)
ADDITIONAL PARTS AND HARDWARE
PART 20 FIREBOX
1 PC
PART 21 FIREBOX SHELF
1 PC
PART 22 FIREBOX SHELF
SUPPORT
2 PC
PART 23 FIREBOX LID
1 PC
PART 24 FIREBOX LID
HANDLE 1 PC
PART 25
FIREBOX
PORCELAIN
COATED
COOKING GRATE
2 PC
PART 26 FIREBOX CHARCOAL
GRATE
2 PC
HARDWARE A SCREW 20 PC
HARDWARE E HINGE PIN
SCREW
2 PC

17
IF HEAVY DUTY GRILL/SMOKER IS ALREADY FULLY ASSEMBLED, FOLLOW THESE STEPS FIRST:
1.) Remove “Part 11” (Side Door) by sliding door off of “Part 18” (Hinge). Set aside.
2.) Unscrew the 2 pieces of “Hardware A” (Screw) and remove “Part 18” (Hinge) from Main Body. Set aside.
3.) Unscrew the 1 piece of “Hardware A” (Screw) and remove “Part 17” (Latch Receiver) from Main Body. Set aside.w) and remove “Part 17” (Latch Receiver) from Main Body. Set aside.
11
A (2 pc.), 18
A, 17

18
STEP 18: Unscrew 2 pieces of “Hardware E” (Hinge Pin Screw) from “Part 23” (Firebox Lid) and slide Lid off of
Firebox. Set aside.
-- E --
STEP 19: Be sure to have 2 people complete this step! Using 9 pieces of “Hardware A” (Screw), attach “Part 20”
(Firebox) to “Part 1” (Main Body). Attach the top screws first to make it easier to attach the bottom screws.
A
20
A

19
STEP 20: Using 1 piece of “Hardware A” (Screw), attach “Part 17” (Latch Receiver) to Firebox. Using 2 pieces of
“Hardware A” (Screw), attach “Part 18” (Hinge) to Firebox.
STEP 21: Slide the hinge pins of “Part 11” (Side Door) into the Hinge and use latch to open and close Side Door for
ash cleanout.
A
A
11

20
STEP 22: Using 2 pieces of “Hardware A” (Screw), attach “Part 21” (Firebox Shelf) to front of Firebox. Using 4
pieces of “Hardware A” (Screw), attach both pieces of “Part 22” (Firebox Shelf Support) to the Firebox and the Firebox
Front Shelf.
AA
STEP 23: Slide Firebox Lid onto Firebox. Using 2 pieces of “Hardware E” (Hinge Pin Screw), secure lid onto Firebox.