Char-Broil 463420509 User Manual

2.3 Mb
Rev. 01 • 06-16-08 • 80017503


MODEL 463420509

IMPORTANT: Fill out the product record information below.

Serial Number

See rating label on grill for serial number.

Date Purchased

For support and to register your grill, please visit us at

If you have questions or need assistance during assembly,

please call 1-800-241-7548.

Estimated assembly time: 35-40minutes

The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Char-Broil®;America's Legendary Barbeque Company®; American Gourmet®; Bandera®; BrushHawg®; CB940®;Char-Diamonds®;Char-BroilCharcoal/Gas®; DiamondFlame®; Everybody Grills®; Everybody Outside®; FastStart®; Fireball®; Firenzy®; FlavorMaster®; Grill2Go®; Grill2Go® Express®; Grill Lovers®; H20 Smoker®; Keepers of the Flame®; New Braunfels Smoker Company®; Oklahoma Joe's®; Patio Bistro®; Patio Caddie®; Patio Kitchen®; Precision Flame®; Quantum®;

Santa Fe®; Sear and Grill®; Sierra®; Signature Series®; The Big Easy®; The Minute Grill®; Trentino®; Wild West Tradition®; and the following marks:



The following are trademarks of W.C. Bradley Co.: Commercial Series™; Designer Series™; Grill2Go® Advantage™; Longhorn™; Double Chef™;

QuickSet™; Ready When You Are™; Hog and Yard Bird™; You Bring the Party™; SureFire™; Universal Grill Parts™

TEC™ is a trademark of Tec Infrared Grills.

Protected under one or more of the following U.S. Patents: 4,989,579; 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,114,666; 6,135,104; 6,209,533; 6,279,566; 6,331,108; 6,484,900; 6,526,876; 6,595,197; 6,640,799; 6,640,803; 6,729,873; 6,739,473; 6,749,424; 6,863,100; 6,935,327; 6,951,213; 6792,935; 7,047,590; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910; D405,643; D406,005; D406,009 ; D413,043; D413,229; D414,982; D415,388; D416,164; D416,441; D417,587; D417,588; D422,516; D423,876; D428,303; D430,772; D435,396; D436,004; D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D443,464; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D450,544; D451,759; D454,028; D454,031; D455,205; D455,206; D456,202; D456,222; D456,223; D457,789; D458,520; D458,760; D458,802; D459,088; D459,148 D459,149; D459,161; D459,163; D459,586; D459,943; D460,312; D460,313; D460,318; D461,359; D465,123; D465,693; D466,307; D466,439; D466,752; D473,414; D474,371; D477,498; D477,501; D477,504; D477,506; D477,746; D478,471; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359; D504,048; D530,098; D535,000; Canada: 87,743; 87,744; 97,504; 99,355; 102,037; 104,200; 2,315,567; 2,336,036; France: 010,231; 010,422; 010,590; 010,849; 1,089,646; Germany: 1,089,646; South Korea: 384,565; China: 99,127,066.5; United Kingdom: 2,099,402; 1,089,646. Other Patents Pending.

© 2008 W.C. Bradley Company

© 2008 Char-Broil,LLC Columbus, GA 31902

Printed in China


For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Grilling Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-26

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-29

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Safety Symbols

The symbols and boxes shown below explain what each heading means. Read and follow all of the messages found throughout the manual.


WARNING: Indicates an potentially hazardous situation which, if not avoided, could result in death or serious injury.


CAUTION: Indicates a potentially hazardous situation or unsafe practice which, if not avoided, may result in minor or moderate injury.


DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.


If you smell gas:

1.Shut off gas to the appliance.

2.Extinguish any open flame.

3.Open lid.

4.If odor continues, keep away from the appliance and immediately call your gas supplier or your fire department.


1.Do not store or use gasoline or other flammable liquids or vapors 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.


For residential use only. Do not use for commercial




Read and follow all safety statements, assembly instructions, and use and care directions before attempting to assemble and cook.


Leave this manual with consumer.


Keep this manual for future reference.


Failure to follow all manufacturer’s instructions could result in serious personal injury and/or property damage.


Some parts may contain sharp edges – especially as noted in the manual! Wear protective gloves if necessary.




1.Combustion by-productsproduced when using this product contain chemicals known to the State of California to cause cancer, birth defects, and other reproductive harm.

2.This product contains chemicals, including lead and lead compounds, known to the State of California to cause cancer, birth defects or other reproductive harm.

Wash your hands after handling this product.

Installation Safety Precautions

Use grill, as purchased, only with LP (propane) gas and the regulator/valve assembly supplied. A conversion kit must be purchased for use with natural gas.

Grill installation must conform with local codes, or in their absence of local codes, with either the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, Natural Gas and Propane Installation Code, CSA B149.1, or Propane Storage and Handling Code, B149.2, or the Standard for Recreational Vehicles, ANSI A 119.2/NFPA 1192, and CSA Z240 RV Series, Recreational Vehicle Code, as applicable.

All electrical accessories (such as rotisserie) must be electrically grounded in accordance with local codes, or

National Electrical Code, ANSI / NFPA 70 or Canadian Electrical Code, CSA C22.1. Keep any electrical cords and/or fuel supply hoses away from any hot surfaces.

This grill is safety certified for use in the United States and/or Canada only. Do not modify for use in any other location. Modification will result in a safety hazard.


Do not attempt to repair or alter the hose/valve/regulator for any “assumed” defect. Any modification to this assembly will void your warranty and create the risk of a gas leak and fire. Use only authorized replacement parts supplied by manufacturer.


GRILLING GUIDE – Getting Started

First Time Use

Read your Assembly Manual and ensure the grill is put together properly. Remove all Point-of-Purchaseadvertising material from all grill surfaces before first use. We recommend operating your grill on its highest setting for15-20minutes prior to your first use. This aids in removing the oils used during manufacturing.

Lava Rock / Briquettes

This gas grill has been designed, engineered, and tested to be used with flame tamers or heat distribution plates to provide more even heating, improve the cleaning process, and reduce flare-ups.The addition of after market lava rocks, charcoal, or briquettes of any type will cause poor combustion and increase the likelihood of a grease fire, and is not recommended. Using briquettes, lava rock, or charcoal in this grill will void your warranty. For extra smoke flavor, we recommend using a smoker box with wood chips.


The temperature gauge in the hood of your new grill measures air temperature. The air temperature inside your grill will never be as hot as the temperature at the cooking surface.

Note: Since 1995, all regulators (the part that attaches to the gas tank to regulate the flow of gas) have included a safety feature that restricts gas flow in the event of a gas leak. You can inadvertently activate this safety feature without having a gas leak. This typically occurs when you turn on the gas using the grill control knob before you turn on the LP tank valve. If the gas regulator safety feature activates, the grill will only reach temperatures between 250°F and 300°F even with all burners on the high setting.


Coupling Nut

If your grill is not getting hotter than 250°F to 300°F these

steps should be taken first to reset the gas regulator safety


1.Open the grill lid.

2.Turn off all knobs on the control panel in front.

3.Turn off the tank knob.

4.Disconnect the regulator from the LP tank.

5.Wait 30 seconds.

6.Reconnect the regulator to the LP tank.

7.Slowly open the LP tank knob all the way. Do not put excessive force on the valve at the full open position to avoid damaging the valve.

8.Turn on the appropriate control knob and light the grill per the instructions on the control panel.

An illustration of this process is included in this Product Guide. See Troubleshooting section for additional information.

Pre-HeatingYour Grill

Just like your home oven, your grill should be pre-heatedto provide optimum performance.Pre-heatthe grill on high for 1015 minutes – longer if weather conditions require. Please refer to the lighting instructions inside the Product Guide if you have questions about how to light your grill. Amatch-lightchain and hole is provided for your convenience.


GRILLING GUIDE – Grilling 101

Outdoor grilling is really quite simple. You'll succeed with burgers, dogs, or steaks usually on your very first try. With experience, you will learn how to work with your grill, creating more imaginative meals all the time. This knowledge makes up the art of grilling. Before you start grilling, organize your food according to cooking technique and required cooking time, and optimize the use of your grilling area.

Direct Cooking

Direct cooking involves grilling your meat directly over high heat. It is perfect for searing steaks, chops, and other smaller pieces of meat and vegetables that quickly make their way to the table.

Indirect Cooking

Indirect cooking utilizes select burners to circulate heat throughout the grill, without direct contact between the meat and the flame. The meat is placed over the burner that is 'off'. This method is generally used to slow cook large cuts of meat and poultry. A pan can be placed underneath the meat to catch grease and food drippings, and helps minimize clean-up.

Rotisserie Cooking

Rotisserie cooking is best for 'round' meat, such as large roasts, whole poultry, and pork. It generally requires an accessory motor and spit rod that allows the meat to be turned at a constant speed. Rotisserie cooking is best done in front of a special rotisserie burner, or utilizing an indirect cooking burner arrangement. A pan can be placed underneath the meat to catch grease and food drippings, and helps minimize clean-up.

Food Safety

Food safety is a very important part of enjoying the outdoor cooking experience. To keep food safe from harmful bacteria, follow these four basic steps:

Clean: Wash hands, utensils, and surfaces with hot soapy water before and after handling raw meat.

Separate: Separate raw meats from ready-to-eatfoods to avoid cross contamination. Use a clean platter and utensils when removing cooked foods.

Cook: Cook meat and poultry thoroughly to kill bacteria. Use a thermometer to ensure proper internal food temperatures. Chill: Refrigerate prepared foods and leftovers promptly.


GRILLING GUIDE – Tips & Tricks

Cooking on your new grill is a hands-onexperience, and it is recommended to remain outside with your grill while cooking. Grilling can be affected by many external conditions. In cold weather, you will need more heat to reach an ideal cooking temperature, and grilling may take longer. The meat's internal temperature and thickness can also affect cooking times. Cold and thicker meats will take longer to cook.

Internal Meat Temperatures

Meat cooked on a grill often browns very fast on the outside. Therefore, use a meat thermometer to ensure it has reached safe internal temperatures.

USDA Recommended Safe Minimum

Internal Temperatures

Beef, Veal, Lamb, Steaks, & Roasts

145° F


145° F


160° F

Beef, Veal, Lamb Ground

160° F

Egg Dishes

160° F

Turkey, Chicken & Duck Whole,

165° F

Pieces & Ground


Please refer to the USDA for complete, up-to-dateinformation. Our internal temperature chart is based on USDA standards for meat doneness. Check it out


Sauces containing sugars and fats can cause flare-ups,and your food may burn. In general, apply these sauces during the final 10 minutes of cooking. Keep in mind, use of excessive sauces or glazes will also require extra cleaning afterwards.

Marinades and Rubs

To enhance the flavor of grilled foods, a liquid marinade or dry rub can be used prior to cooking. Meat can be either soaked or injected with liquid marinade up to 24 hours prior to grilling. Dry rubs can be applied directly to the meat immediately before grilling.

Wood Chips

For extra smoke flavor when grilling, try adding wood chips. Soak the chips in water for approximately 30 minutes before adding to a smoke box or pan. Place smoke box or pan on top of the cooking grate above the flame. Turn grill on high until the wood starts to smoke. Reduce heat to desired temperature for cooking, and place food on cooking grate as desired. Close lid to retain more smoke. Hardwood varieties that work particularly well with grilled foods include Alder, Apple, Cherry, Grapevines, Hickory, Mesquite, Oak, Rosemary and Sassafras.


Metal skewers should be flat, with long handles. Round skewers allow food to roll when turned, so it may not cook as evenly. Use metal skewers when cooking meat kabobs. Wooden skewers should be soaked in water for an hour before use, and are best used for quick cooking foods such as vegetables and fruits.


Use tongs or a spatula to handle the food instead of a fork, and don't turn the food too

often. Piercing the food with a fork will release juices that you want in the meat, and may cause flare-ups.


GRILLING GUIDE – Cleaning Your Grill

Why Clean?

We've all heard the saying, 'an ounce of prevention is worth a pound of cure.’ This is great advice when it comes to keeping your grill clean.

Routine Care

Periodic cleaning of this grill is necessary, as grill fires can occur when grease and food debris collect in the bottom of the grill. After each use, remove any remaining food particles from the cooking grate and inside of the grill using a grill brush. Do this after the grill has cooled down, yet is still warm. It is much easier to clean food particles while warmth is still present, than after the food particles have completely cooled and hardened. This grill is not designed to be 'burned off' by closing the lid and turning the burners on High for an extended time. The excessive heat generated can cause leftover grease to catch fire, and can cause permanent damage to your grill.

General Cleaning

Plastic parts: Wash with warm soapy water and wipe dry. Do not use abrasive cleaners, degreasers or a concentrated grill cleaner on plastic parts. Damage to and failure of parts can result.

Porcelain surfaces: Because of glass-likecomposition, most residue can be wiped away with baking soda/water solution or glass cleaner. Usenon-abrasivescouring powder for stubborn stains.

Painted surfaces: Wash with mild detergent or non-abrasivecleaner and warm water. Wipe dry with a softnon-abrasivecloth.

Stainless steel surfaces: Stainless steel can rust under certain conditions. This can be caused by environmental conditions such as chlorine or salt water, or improper

cleaning tools such as wire or steel wool. It can also discolor due to heat, chemicals, or grease build-up.To maintain your grill's high quality appearance, wash with mild detergent and warm water, or use a stainless steel grill cleaner.Baked-ongrease deposits may require the use of an abrasive plastic cleaning pad. Use only in direction of brushed finish to avoid damage. Do not use abrasive pad on areas with graphics.

Cooking surfaces: If a bristle brush is used to clean any of the grill cooking surfaces, ensure no loose bristles remain on cooking surfaces prior to grilling. It is not recommended to clean cooking surfaces while grill is hot.

Storing Your Grill

Clean cooking grates.

Store grill in dry location.

When LP cylinder is connected to grill, store outdoors in a well ventilated space and out of reach of children.

Cover grill if stored outdoors. Choose from a variety of grill covers offered by manufacturer.

Store grill indoors ONLY if LP cylinder is turned off, disconnected, and removed from grill. Never store LP cylinder indoors.

When removing grill from storage, follow the 'Cleaning the Burner Assembly' instructions in the Use and Care section of the Product Guide.


Spiders like to make their homes in the venturi tubes of grills. These must be inspected and cleaned regularly to ensure there are no blockages. Refer to the Use and Care portion of this Product Guide for complete information.




NEVER store a spare LP tank under or near grill or in enclosed areas

Never fill the cylinder beyond 80% full.

An overfilled or improperly stored tank is a hazard due to possible gas release from the safety relief valve.

If you see, smell or hear escaping gas, immediately get away from the LP tank/grill and call your fire department.

If the above is not followed exactly, a fire causing death or serious injury may occur.

LP Tank Removal, Transport And Storage

Turn OFF all control knobs and LP tank valve. Turn coupling nut counterclockwise by hand only - do not use tools to disconnect. Lift LP tank wire upward off of LP tank collar, then lift LP tank up and off of support bracket. Install safety cap onto LP tank valve. Always use cap and strap supplied with valve.

Failure to use safety cap as directed may result in serious personal injury and/or property damage.

LP Tank Valve

Safety Cap

Retainer Strap

A disconnected LP tank in storage or being transported must have a safety cap installed (as shown). Do not store an LP tank in enclosed spaces such as a carport, garage, porch, covered patio or other building. Never leave an LP tank inside a vehicle which may become overheated by the sun.

Do not store an LP tank in an area where children play.

LP Cylinder

The LP cylinder used with your grill must meet the following requirements:

Use LP cylinders only with these required measurements: 12" (30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.) capacity maximum.

LP cylinders must be constructed and marked in accordance with specifications for LP cylinders of the U.S. Department of Transportation (DOT) or for Canada, CAN/CSA-B339,cylinders, spheres and tubes for transportation of dangerous goods. Transport Canada (TC). See LP cylinder collar for marking.

LP cylinder valve must have:

Type 1 outlet compatible with regulator or grill.

Safety relief valve.

• UL listed Overfill Protection

OPD Hand Wheel

Device (OPD). This OPD safety

feature is identified by a unique triangular hand wheel. Use

only LP cylinders equipped with this type of valve.

LP cylinder must be arranged for vapor withdrawal and include collar to protect LP cylinder valve. Always keep LP cylinders in upright position during use, transit or storage.

LP cylinder in upright position for

vapor withdrawal

LP (Liquefied Petroleum Gas)

LP gas is nontoxic, odorless and colorless when produced. For Your Safety, LP gas has been given an odor (similar to rotten cabbage) so that it can be smelled.

LP gas is highly flammable and may ignite unexpectedly when mixed with air.

LP Cylinder Filling

Use only licensed and experienced dealers.

LP dealer must purge new cylinder before filling.

Dealer should NEVER fill LP cylinder more than 80% of LP cylinder volume. Volume of propane in cylinder will vary by temperature.

A frosty regulator indicates gas overfill. Immediately close LP cylinder valve and call local LP gas dealer for assistance.

Do not release liquid propane (LP) gas into the atmosphere. This is a hazardous practice.

To remove gas from LP cylinder, contact an LP dealer or call a local fire department for assistance. Check the telephone directory under “Gas Companies” for nearest certified LP dealers.


LP Tank Exchange

Many retailers that sell grills offer you the option of replacing your empty LP tank through an exchange service. Use only those reputable exchange companies that inspect, precision fill, test and certify their cylinders. Exchange your tank only for an OPD safety feature-equipped tank as described in the "LP Tank" section of this manual.

Always keep new and exchanged LP tanks in upright position during use, transit or storage.

Leak test new and exchanged LP tanks BEFORE connecting to grill.

LP Tank Leak Test

For your safety

Leak test must be repeated each time LP tank is exchanged or refilled.

Do not smoke during leak test.

Do not use an open flame to check for gas leaks.

Grill must be leak tested outdoors in a well-ventilatedarea, away from ignition sources such as gas fired or electrical appliances. During leak test, keep grill away from open flames or sparks.

Use a clean paintbrush and a 50/50 mild soap and water solution. Brush soapy solution onto areas indicated by arrows in figure below. Leaks are indicated by growing bubbles.


If “growing” bubbles appear do not use or move the LP tank. Contact an LP gas supplier or your fire department!

useDo not household cleaning agents.Damage to gas train components can result.

Connecting Regulator To The LP Tank

1.LP tank must be properly secured onto grill. (Refer to assembly section.)

2.Turn all control knobs to the OFF position.

3.Turn LP tank OFF by turning OPD hand wheel clockwise to a full stop.

4.Remove the protective cap from LP tank valve. Always use cap and strap supplied with valve.





ff C






OPD Hand Wheel

Type 1 outlet with thread on outside

Safety Relief Valve

Strap and Cap

Do not use a POL transport plug (plastic part with external threads)! It will defeat the safety feature of the valve.

5.Hold regulator and insert nipple into LP tank valve. Hand-tightenthe coupling nut, holding regulator in a straight line with LP tank valve so as not to crossthread the connection.

Nipple has to be centered

into the LP tank valve.



Hold coupling nut and regulator

as shown for proper connection

to LP cylinder valve.

Leak Testing Valves, Hose and Regulator

1.Turn all grill control knobs to OFF.

2.Be sure regulator is tightly connected to LP cylinder.

3.Completely open LP cylinder 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.

6.Turn the coupling nut clockwise and tighten to a full stop. The regulator will seal on the back-checkfeature in the LP cylinder valve, resulting in some resistance.An additional one-half to three-quarters turn is required to complete the connection. Tighten by hand only – do not use tools.


If you cannot complete the connection, disconnect regulator and repeat steps 5 and 6. If you are still unable to complete the

connection, do not use this regulator!


Do not insert any tool or foreign object into the valve outlet or safety relief valve. You may damage the valve and cause a leak. Leaking propane may result in explosion, fire, severe personal injury, or death.


Outdoor gas appliance is not intended to be installed in or on a boat.

Outdoor gas appliance is not intended to be installed in or on an RV.

Never attempt to attach this grill to the self-containedLP gas system of a camper trailer or motor home.

Do not use grill until leak-tested.

If a leak is detected at any time, STOP and call the fire department.

If you cannot stop a gas leak, immediately close LPcylinder valve and call LP gas supplier or your fire department!

NOTE: Sideburner

shelf fascia not

shown for clarity.

5.If “growing” bubbles appear, there is a leak. Close LP cylinder valve immediately and retighten connections.If leaks cannot be stopped do not try to repair. Call for replacement parts.

6.Always close LP cylinder valve after performing leak test by turning hand wheel clockwise.