Char-Broil 463720110 User Manual

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PRODUCT GUIDE

MODEL 463720110

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 www.charbroil.com

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: Caldera®; Charcoal2Go®; Char-Broil®;America's Legendary

Barbeque Company®; American Gourmet®; Bandera®; Brush Hawg®; CB 940®; Char-Diamonds®;Char-BroilCharcoal/Gas®; Everybody Grills®; Everybody Outside®; FastStart®; Grill 2 Go®; Grill 2 Go® Express®; Grill Lovers®; Infrared Grilling That’s All About U®; Keepers of the Flame®; New Braunfels Smoker

Company®; Patio Bistro®; Patio Caddie®; Patio Kitchen®; Pro-Sear®;RED®; Quantum®; Santa Fe®; Sear and Grill®; Sierra®; Signature Series®; Sure2Burn®; The Big Easy®; Trentino®; U®; Wild West Tradition®; and the following marks:

® ®

The following are trademarks of W.C. Bradley Co.: Advantage Series™; Auto-Clean™;ChefTested™; Commercial Series™; Designer Series™;; Diamond Flame™; Double Chef™; Fireball™; Firenzy™; FlavorMaster™;Front Avenue™; Grill 2 Go® Advantage™; Hog and Yard Bird™; H20 Smoker™; Infrared. Grilling’s Juicy Little Secret™; Incredible Taste. Infallible Results™; Infrared Inside™; Insure™; Let’s Grill Something Together™;Lev-Alert™;Longhorn™; Magneto™; Precision Flame™; Quick2Burn™; QuickSet™; Ready When You Are™; Season, Set, And Savor™; Sizzle On The Grill™; Signature Series™; SureFire™; The Minute Grill™;Torchfork™; Universal Grill Parts™; You Bring the Party™ TEC™ is a trademark of Tec Infrared Grills.

Protected under one or more of the following U.S. Patents: 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,135,104; 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; 6,792,935; 6,951,213; 7,047,590; 7,516,693; 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; D423,274; 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:D97,504;D99,355; D102,037; D104,200;D108,377; 2,315,567; France:D010,231;D010,422;D010,590;D010,849; 1,089,646; South Korea: 384,565; United Kingdom: 2,099,402. Other Patents Pending. © 2009 W.C. Bradley Company

© 2008 Char-Broil,LLC Columbus, GA 31902

Printed in China

Assembly instructions © 2009

06/25/09 • G305-001-190801

TABLE OF CONTENTS

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

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

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

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

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

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-27

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29

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

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

CAUTION

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

DANGER

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

DANGER

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.

WARNING

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.

CAUTION

For residential use only. Do not use for commercial

cooking.

THIS GRILL IS FOR OUTDOOR USE ONLY.

CAUTION:

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

INSTALLER/ASSEMBLER:

Leave this manual with consumer.

CONSUMER:

Keep this manual for future reference.

WARNING:

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

CAUTION:

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

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING

 

 

 

 

 

 

 

CAUTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CALIFORNIA PROPOSITION 65

 

 

Using pots larger than 6 quarts in capacity could

 

1. Combustion by-productsproduced when using

 

 

exceed weight limit of the

 

this product contain chemicals known to the State of

 

 

side burner shelf

 

California to cause cancer, birth defects, and other

 

 

or side shelf,

 

reproductive harm.

 

 

resulting in failure

 

2. This product contains chemicals, including lead

 

 

of grill cart

 

and lead compounds, known to the State of

 

 

components.

 

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 for dual fuel grills 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.

WARNING

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.

3

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.

Temperature

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.

Regulator

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

device:

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.

4

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.

5

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

Fish

145° F

Pork

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 atwww.isitdoneyet.gov

Sauces

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.

Skewers

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.

Utensils

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.

6

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.

Critters

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.

7

Retainer Strap

USE AND CARE

DANGER

NEVER store a spare LP cylinder under or near the appliance or in an enclosed area.

Never fill a cylinder beyond 80% full.

An over filled or improperly stored cylinder is a hazard due to possible gas release from the safety relief valve. This could cause an intense fire with risk of property damage, serious injury or death.

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

LP Cylinder Removal, Transport and Storage

•Turn OFF all control knobs and LP cylinder valve. Turn coupling nut counterclockwise by hand only - do not use tools to disconnect. Loosen cylinder screw beneath bottom shelf, then lift LP cylinder up and out of cart. Install safety cap onto LP cylinder 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.

•A disconnected LP cylinder in LP Cylinder Valve

 

storage or being transported

 

must have a safety cap installed (as shown).

 

Do not store an LP cylinder in enclosed spaces

 

such as a carport, garage, porch, covered

Safety

patio or other building. Never leave an LP cylinder

inside a vehicle which may become overheated

Cap

 

by the sun.

•Do not store an LP cylinder 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 cylinderbefore filling.

Dealer shouldNEVER 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.

8

LP Cylinder Exchange

Connecting Regulator to the LP Cylinder

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

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

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

•Place dust cap on cylinder valve outlet whenever the cylinder is not in use. Only install the type of dust cap on the cylinder valve outlet that is provided with the cylinder valve. Other types of caps or plugs may result in leakage of propane.

LP Cylinder Leak Test

For your safety

Leak test must be repeated each time LP cylinder 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 awell-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.

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

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

2.Turn all control knobs to the OFF position.

3.Turn LP cylinder OFF by turninghand-wheelclockwise to afull stop.

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

lo

ck

 

wi

ffC

 

se

O

 

 

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.

WARNING

If “growing” bubbles appear do not use or move the LP

cylinder. Contact an LP gas supplier or your fire

department!

5.Hold regulator and insert nipple into LP cylinder valve.Hand-tightenthe coupling nut, holding regulator in a straight line with LP cylinder valve so as not tocross-threadthe connection.

Nipple has to be centered into the LP cylinder valve.

9

Straight

Hold coupling nut and regulator as shown for proper connection to LP cylinder valve.

6.Turn the coupling nut clockwise and tighten to a full stop. The regulator will seal on theback-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.

NOTE:

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!

DANGER

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.

WARNING

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!

10

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 arushing sound, turn gas off immediately. There is a major leak at the connection.Correct before proceeding.

4.Brush soapy solution onto areas circled below, or other similar fittings on your grill.

 

 

 

 

 

 

 

 

NOTE: Your grill

 

 

NOTE: Sideburner

 

may NOT be

 

 

shelf fascia not

 

equipped with a

 

 

shown for clarity.

 

sideburner.

 

 

 

 

 

 

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.

WARNING

For Safe Use Of Your Grill And To Avoid Serious

Injury:

Do not let children operate or play near grill.

Keep grill area clear and free from materials that burn.

Do not block holes in bottom or back of grill.

Check burner flames regularly.

Use grill only inwell-ventilatedspace. NEVER use in enclosed space such as carport, garage, porch, covered patio, or under an overhead structure of any kind.

Do not use charcoal or ceramic briquets in a gas grill. (Unless briquets are supplied with your grill.)

•Use grill at least 3 ft. from any wall or surface. Maintain 10 ft. clearance to objects that can catch fire or sources of ignition such as pilot lights on water heaters, live electrical appliances, etc.

•Apartment Dwellers:

Check with management to learn the requirements and fire codes for using an LP gas grill in your apartment complex. If allowed, use outside on the ground floor with a three (3) foot clearance from walls or rails. Do not use on or under balconies.

•NEVER attempt to light burner with lid closed. A buildup of non-ignitedgas inside a closed grill is hazardous.

•Never operate grill with LP tank out of correct position specified in assembly instructions.

•Always close LP tank valve and remove coupling nut before moving LP tank from specified operation position.

Safety Tips

sBefore opening LP cylinder valve, check the coupling nut for tightness.

sWhen grill is not in use, turn off all control knobs and LP cylinder valve.

sIf the outdoor cooking gas appliance is not in use, the gas must be turned off at the supply cylinder. Storage of an outdoor cooking gas appliance indoors is permissible only if the cylinder is disconnected and removed from the appliance.

sNever move grill while in operation or still hot.

Uselong-handledbarbecue utensils and oven mitts to avoid burns and splatters.

sMaximum load for side shelves is 10 lbs.

greaseThe cup must be inserted into grease clip and emptied after each use. Do not remove grease cup until grill has completely cooled.

sClean grill often, preferably after each cookout. 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.

sIf you notice grease or other hot material dripping from grill onto valve, hose or regulator, turn off gas supply at once. Determine the cause, correct it, then clean and inspect valve, hose and regulator before continuing. Perform a leak test.

sThe regulator may make a humming or whistling noise during operation. This will not affect safety or use of grill.

useOnly the pressure regulator and hose assembly supplied with this grill. Replacement pressure regulator and hose assemblies must be specified or supplied by Char-Broil,LLC.

sIf you have a grill problem see the "Troubleshooting Section".

sIf the regulator frosts, turn off grill and LP cylinder valve immediately. This indicates a problem with the cylinder and it should not be used on any product. Return to supplier!

CAUTION

•Putting out grease fires by closing the lid is not possible. Grills are well ventilated for safety reasons.

•Do not use water on a grease fire. Personal injury may result. If a grease fire develops, turn knobs and LP tank off.

•Do not leave grill unattended while preheating or burning off food residue on high. If grill has not been regularly cleaned, a grease fire can occur that may damage the product. Follow instructions on General Grill Cleaning and Cleaning The Burner Assembly to prevent grease fires.

11

Ignitor Lighting

sDo not lean over grill while lighting.

1.Turn OFF gas burner control valves.

2.Turn ON gas at LP cylinder.

3.Open lid during lighting.

4.To ignite, turn left knob to the HI position.

5.Push IGNITOR button rapidly.

6.If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure.

7.To ignite right burner, turn knob to the HI position.

If ignitor does not work, follow match lighting instructions. After Lighting: Turn knobs to HI position forwarm-up.

WARNING

Turn controls and gas source or tank OFF when not

in use.

CAUTION

If burner does not light, turn knobs to OFF, wait 5 minutes, and try again. Always close valve during the 5 minute waiting period. If the burner does not ignite with the valve open, gas will continue to flow out of the burner and could accidentally ignite with risk of injury.

Match-Lighting

sDo not lean over grill while lighting.

1.Turn OFF gas burner control valves.

2.Turn ON gas at LP cylinder.

3.Open lid during lighting.

4.Place match into match holder (hanging from side of cart). Strike the match.

5.Place lit match through the match light hole and near the burner. Push in and turn left knob to the HI position.

Be sure the burner lights and stays lit.

6.Light right burner by pushing knob in and turning to the HI position.

Sideburner Ignitor Lighting

1.Turn OFF gas burner control valves.

2.Turn ON gas at LP cylinder.

3.To ignite SIDEBURNER, open sideburner cover.

4.Turn sideburner knob to the HI position. Push IGNITOR button rapidly.

5.If sideburner does not light in 5 seconds, turn knob to OFF, wait 5 minutes, then repeat lighting procedure.

Sideburner Match Lighting

1.Turn ON gas at LP cylinder.

2.Hold lit match to any port on the burner. Push in and turn

sideburner knob to the HI position. Be sure burner lights and stays lit.

Burner Flame Check

Remove cooking grates and flametamers. Light burner, rotate knobs from HI toLOW. You should see

a smaller flame in LOW position than seen onHI. Always check flame prior to each use. If only low flame is seen refer to "Sudden drop or low flame" in theTroubleshooting Section.

HI

LOW

Hose Check

Before each use, check to see if hoses are cut, worn or kinked. Replace damaged hoses before using grill. Use only valve/hose/regulator specified in the Parts List.

Normal

Kinked

Hose

Hose

Turning Grill Off

Turn all knobs to OFF position. Turn LP tank off by turning OPD hand wheel clockwise to a full stop.

Ignitor Check

Turn gas off at LP tank. Press and hold ignitor button. "Click" should be heard and spark seen each time between collector box or burner and electrodes. See "Troubleshooting" if no click or spark.

Valve Check

Important: Make sure gas is off at LP tank before checking valves. Knobs lock in OFFposition. To check valves, first push in knobs and release, knobs should spring back. If knobs do not spring back, replace valve assembly before using grill. Turn knobs to LOWposition then turn back to OFFposition. Valves should turn smoothly.

General Grill Cleaning

Do not mistake brown or black accumulation of grease and smoke for paint. Interiors of gas grills are not painted at the factory (and should never be painted). Apply a strong solution of detergent and water or use a grill cleaner with scrub brush on insides of grill lid and bottom. Rinse and allow to completely air dry.Do not apply a caustic grill/oven cleaner to painted surfaces.

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

Porcelain surfaces: Because ofglass-likecomposition, most residue can be wiped away with baking soda/water solution or specially formulated cleaner. Use nonabrasive scouring powder for stubborn stains.

Painted surfaces: Wash with mild detergent or nonabrasive cleaner and warm soapy water. Wipe dry with a soft nonabrasive cloth.

12

Plated wire grates: Wash grates with concentrated grill cleaner or use soap and water solution. Dry thoroughly and store indoors between cookouts.

Stainless steel surfaces: To maintain your grill’s high quality appearance, wash with mild detergent and warm soapy water and wipe dry with a soft cloth after each use.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 in dry location.

When LP cylinder is connected to grill, store outdoors in a wellventilated 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 and

disconnected, removed from grill and stored outdoors.

When removing grill from storage, follow “Cleaning the Burner Assembly” instructions before starting grill.

CAUTION

SPIDER ALERT!

VALVE

AIR

VENTURI

 

SHUTTER

 

If you notice that your grill is getting hard to light or that the flame isn’t as strong as it should be, take the time to check and clean the venturi’s.

LIFT OUT

BURNER ASSEMBLY

REMOVE

BURNER

CLIPS

CLEAN OUT

SPIDER WEBS

VENTURI

INSIDE VENTURI

In some areas of the country, spiders or small insects have been known to create “flashback” problems. The spiders spin webs, build nests and lay eggs in the grill’s venturi tube(s) obstructing the flow of gas to the burner. The backed-upgas can ignite in the venturi behind the control panel. This is known as a flashback and it can damage your grill and even cause injury.

To prevent flashbacks and ensure good performance the burner and venturi assembly should be removed from the grill and cleaned before use whenever the grill has been idle for an extended period.

Cleaning the Burner Assembly

Follow these instructions to clean and/or replace parts of burner assembly or if you have trouble igniting grill.

1.Turn gas OFF at control knobs and LP cylinder.

2.Remove cooking grate and heat tent.

3.Under grill remove grease cup, disconnect ignitor wire from burner.

4.Inside grill remove burner assembly (A), clean ceramic portion of electrode with rubbing alcohol and a swab.

5.Clean outside of burner with soap and water. Lay burner upside down on flat surface, insert garden hose to force water through tubes. Make sure water comes out of all burner holes. Open clogged holes with a thin wire. Shake out excess water and examine holes. Due to normal wear and corrosion some holes may become enlarged. If any large cracks or holes are found replace burner.

6.If grill is to be stored, coat burner lightly with cooking oil. Wrap in protective cover to keep insects out.

7.If not storing grill after cleaning, replace burner into grill bottom.

8.Check that the burners are not damaged. Because of normal wear and corrosion some holes may have enlarged. If you notice large cracks or large holes, replace the burner.

VERY IMPORTANT: Burner tubes must re-engagevalve openings. See illustration (A).

9. Reattach ignitor wire to electrode.

10.Reposition heat tent and cooking grate. Reattach clean grease cup to grease clip.

11.Before cooking again on grill, perform a “Leak Test” and

“Burner Flame Check”.

Correct burner-to-valveengagement

A

Burner Tube

Valve

B

13

LIMITED WARRANTY

This warranty only applies to units purchased from an authorized retailer. Manufacturer warrants to the original consumer-purchaser only that this product shall be free from defects in workmanship and materials after correct assembly and under normal and reasonable home use for the periods indicated below beginning on the date of purchase*. The manufacturer reserves the right to require that defective parts be returned, postage and or freightpre-paidby the consumer for review and examination.

SCOPE OF COVERAGE

PERIOD OF COVERAGE

TYPE OF FAILURE COVERAGE

All Parts

1 year from date of purchase*

PERFORATION, MANUFACTURING,

 

 

AND MATERIAL DEFECTS ONLY

 

 

 

*Note: A dated sales reciept WILL be required for warranty service.

The original consumer-purchaserwill be responsible for all shipping charges for parts replaced under the terms of this limited warranty.

This limited warranty is applicable in the United States and Canada only, is only available to the original owner of the product and is not transferable.

Manufacturer requires proof of your date of purchase. Therefore, you should retain your sales slip or invoice. Registering your product is not a substitute for proof of purchase and the manufacturer is not responsible for or required to retain proof of purchase records.

This limited warranty applies to the functionality of the product ONLY and does not cover cosmetic issues such as scratches, dents, corrosions or discoloring by heat, abrasive and chemical cleaners or any tools used in the assembly or installation of the appliance, surface rust, or the discoloration of stainless steel surfaces. RUST is not considered a manufacturing or materials defect.

This limited warranty will not reimburse you for the cost of any inconvenience, food, personal injury or property damage.

ITEMS MANUFACTURER WILL NOT PAY FOR:

1.Shipping cost, standard or expedited, for warranty and replacement parts

2.Service calls to your home.

3.Repairs when your product is used for other than normal, single-familyhousehold or residential use.

4.Damage, failures, or operating difficulties resulting from accident, alteration, careless handling, misuse, abuse, fire, flood,

acts of God, improper installation or maintenance, installation not in accordance with electrical or plumbing codes, or use of products not approved by the manufacturer.

5. Any food loss due to product failures or operating difficulties.

6. Replacement parts or repair labor costs for units operated outside the United States or Canada. 7. Pickup and delivery of your product.

8. Repairs to parts or systems resulting from unauthorized modifications made to the product. 9. The removal and/or reinstallation of your product.

DISCLAIMER OF IMPLIED WARRANTIES and LIMITATION OF REMEDIES

Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. In the event of parts availability issues, the manufacturer reserves the right to substitute like or similar parts that are equally functional.

Manufacturer will not be responsible for any consequential or incidental damages arising from the breach of either this limited warranty or any applicable implied warranty, or for failure or damage resulting from acts of God, improper care and maintenance, grease fire, accident, alteration,

replacement of parts by anyone other than Manufacturer, misuse, transportation, commercial use, abuse, hostile environments (inclement weather,

acts of nature, animal tampering), improper installation or installation not in accordance with local codes or printed manufacturer instructions.

THIS LIMITED WARRANTY IS THE SOLE EXPRESS WARRANTY GIVEN BY THE MANUFACTURER. NO PRODUCT PERFORMANCE SPECIFICATION OR DESCRIPTION WHEREVER APPEARING IS WARRANTED BY MANUFACTURER EXCEPT TO THE EXTENT SET FORTH IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTY PROTECTION ARISING UNDER THE LAWS OF ANY STATE, INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, IS HEREBY LIMITED IN DURATION TO THE DURATION OF THIS LIMITED WARRANTY.

Neither dealers nor the retail establishment selling this product has any authority to make any additional warranties or to promise remedies

in addition to or inconsistent with those stated above. Manufacturer's maximum liability, in any event, shall not exceed the purchase price of the product paid by the original consumer.

NOTE: Some states do not allow an exclusion or limitation of incidental or consequential damages, so some of the above limitations or exclusions may not apply to you. This limited warranty gives you specific legal rights as set foth herein. You may also have other rights which vary from state to state. In the state of California only, if refinishing or replacement of the product is not commercially practicable, the retailer selling this product or the Manufacturer will refund the purchase price paid for the product, less the amount directly attributable to use by the original consumer-purchaserprior to discovery of the nonconformity. In addition, in the state of California only, you may take the product to the retail establishment selling this product in order to obtain performance under this limited warranty.

If you wish to obtain performance of any obligation under this limited warranty, you should

write to:

Consumer Relations

P. O. Box 1240

Columbus, GA 31902-1240

Consumer returns will not be accepted unless a valid Return Authorization is first acquired. Authorized returns are clearly marked on the outside of the package with an RA number and the package is shipped freight/postage pre-paid.Consumer returns that do not meet these standards will be refused.

14

PARTS LIST

Key Qty Description

A1 FIREBOX

B1 IGNITOR

C1 BURNER

D1 COLLECTOR/ ELECTRODE ASSY

E

1

LID

F

1

LOGO PLATE

G1 LEFT SIDE SHELF F/ SB

H1 RIGHT SIDE SHELF

I

1

TANK RETAINER

J

1

MOUNTING BRACKET, F/ SIDE SHELF,

(RF/LB)

 

 

K

1

MOUNTING BRACKET, F/ SIDE SHELF,

(LF/RB)

 

 

L

1

MOUNTING BRACKET, F/ PLASTIC SIDE

SHELF, BACK

 

 

M

1

MOUNTING BRACKET, F/ PLASTIC SIDE

SHELF, FRONT

 

 

N2 CART LEG,UPPER

O1 SIDE BRACE

P

1 RIGHT FRONT LEG,CURVED

Q1 RIGHT BACK LEG,STRAIGHT

R1 LEFT BACK LEG,STRAIGHT

S1 LEFT FRONT LEG,CURVED

T2 BACK BRACE

U2 SUPPORT BRACKET

V1 LEFT FIREBOX SUPPORT

W 1 RIGHT FIREBOX SUPPORT

X1 VALVE HOSE REGULATOR ASSEMBLY

Y1 CONTROL PANEL

Z1 FRONT PANEL

AA1 CONDIMENT BASKET

BB1 AXLE ROD

CC2 LEG EXTENDER

DD3 TANK EXCLUSION WIRE

EE

1

HEAT SHIELD

FF

1

COOKING GRATE

GG

1

SWINGAWAY GRID

HH

1

SIDEBURNER GRATE

II

1

SIDEBURNER

JJ

1

ELECTRODE, F/ SB

KK

1

DRIP PAN

LL

2

WHEEL

Key

Qty

Description

MM

3

KNOB

NN

2

LOWER HINGE

OO

2

UPPER HINGE

PP

1

HANDLE

QQ

1

GREASE CUP

RR

1

GREASE CUP CLIP

SS

1

HEAT TENT

TT

1

MATCH HOLDER

 

 

 

NOT Pictured

1 HARDWARE PACK

1 ASSY INSTRUCTIONS, ENGLISH

1 ASSY INSTRUCTIONS, FRENCH

1 RETAINER CLIP

15

PARTS DIAGRAM

 

OO

 

E

 

 

 

 

 

 

 

 

 

 

 

 

F

 

C

 

 

 

 

 

 

 

 

 

PP

 

D

 

GG

 

 

 

HH

 

 

SS

 

KK

 

 

 

 

 

 

 

 

G

 

FF

RR

 

 

 

 

H

 

II

JJ

 

 

 

 

 

 

 

 

J

V

A

 

L

 

 

 

NN

 

 

EE

 

 

 

M

 

 

 

 

 

 

K

 

 

 

 

 

 

X

 

 

 

 

O

 

Y

N

W

 

N

 

 

 

 

 

R

 

 

 

QQ

 

 

 

 

 

 

 

T

 

 

B

 

 

 

DD

 

I

S

 

 

 

 

 

 

 

 

MM

 

 

 

MM

 

TT

 

T

 

 

 

 

U

 

 

AA

 

 

 

 

Q

P

U

BB

Z

CC

LL

16

ASSEMBLY

1

Hinge Pin

Qty.2

Left leg

Place upper leg as shown. NOTE: Left front and left back legs do not have leg extenders. In front, attach upper leg,

side brace and left front leg (curve) with #10-24x1-1/4’’ machine screw and#10-24 flange nut. In back, attached the left back leg (straight) to upper leg.

Attach support bracket in the third hole from bottom of leg with two hinge pins and twohitch pins (A) .

 

Upper Leg

Hitch Pin

 

Qty.2

 

Left Back Leg

Side

(Straight)

Brace

#10-24x1-1/4’’

 

Hitch Pin

Machine Screw

Qty.1

Support

Bracket

 

Hinge Pin

Left Front Leg

(Curve)

#10-24Flange Nut Qty. 1

A

2

Right leg

 

Place upper leg as shown. Attach upper leg and right front leg (curve) with #10-24x1-1/4’’ machine screws and#10-24

 

flange nuts. Then attach upper leg and right back leg (straight).

 

 

Attach support bracket with #10-24x1-1/4’’machine screwsand #10-24flange nuts.

 

Upper

Leg

 

 

Right Back Leg

(Straight)

 

Support

Bracket

 

 

 

 

 

 

Right Front Leg

 

 

 

(Curve)

 

 

 

#10-24x1-1/4’’

#10-24

Leg Extender

 

Machine Screw

Flange Nut

 

 

Qty.3

Qty. 3

17

3

Front Panel

Lay front legs down on the floor

Slide front panel between legs. Attach with#10-24x2’’ machine screws and#10-24 flange nuts.

Left leg assembly

#10-24

#10-24x2”

Flange Nut

Machine Screw

Qty.4

 

Right leg assembly

#10-24x2”Machine Screw Qty.4

Front panel

4

Back Braces to Cart

Attach back braces with #10-24x1-1/4’’machine screwsand #10-24flange nuts.

Side brace

Back brace

#10-24x1-1/4”Machine Screw Qty.8

Back brace

 

#10-24

#10-24

Flange Nut

Flange Nut

 

Qty.8

 

#10-24x1-1/4”Machine Screw

18

5

Hook tank exclusion wires onto front panel brackets, attach other end to back brace with #8-32x3/8’’ sheet metal screws.

#8-32x3/8’’Sheet Metal Screw

Qty.3

6

Wheel

Turn assembly upside down.

Insert axle rod into wheel, legs and other wheel. Attach with a wheel bushing andhitch pin. Attach all in second hole.

Hitch Pin

Qty.1

Wheel

Axle Rod

Wheel Bushing

Qty.1

 

Wheel bushing

Wheel

Hitch Pin

 

“Cone” side of wheel against leg

19

7Stand cart upright.

In front, slide control panel between left and right legs, attach control panel with#10-24x2’’ machine screws. Place fireboxControl Panel and Firebox Supports

supports onto screws and tighten with #10-24 flange nuts. Tighten all screws.

In back, attach upper firebox support with#10-24x2’’ machine screws and#10-24 flange nuts.

Chamfer edge

Control Panel

Firebox

Support

#10-24Flange Nut Qty.8

#10-24x2”Machine Screw Qty.8

8

Valve / Hose / Regulator and Ignitor

Insert main burner valve and hose between left firebox support and side brace, attach valve/hose/regulator assemble to

control panel with #10-24x1/2’’machine screws.

Attach ignitor to control panel using the stamped nut that’s provided. NOTE: if your grill comes with Snap-inignitor, please see Option.

Snap-inignitor

Option: Snap the

 

ignitor into the

 

control panel.

Main burner valve

#10-24x1/2”Machine Screw Qty.2

Ignitor

Valve/Hose/Regulator

Left firebox support

Stamped nut

Side brace

Hose

Back

of

cart

 

 

 

20

9

Heat Shield

Attach heat shield with #10-24x1/2’’machine screwsand #10-24flange nuts.

Heat Shield

#10-24X1/2”Machine Screw Qty.2

Back of cart

#10-24Flange Nut Qty.2

10

Tank Retainer

Insert tank retainer into side brace and secure with #10-24x3/8’’ wing screw.

#10-24x3/8’’Wing Screw

Qty.1

Wing screw

Tank Retainer

21

11 Burner and Firebox and Control Knobs

Place burner assembly into firebox. Fasten the burner assembly to the firebox using 5x15 fiber washers and#1024x1/2’’ machine screws. Insert two#10-24x1-1/4’’ machine screws from outer firebox, then fasten with two#10-24 flange nuts and5x15 fiber washers from inner. Repeat on the other side(A).

Place firebox onto upper firebox supports. Make sure the venturi tube are located underneath heat shield. Make sure burner tubes are correctly engaged. If burner is not leveled from left to right, adjust the two screws attaching valve to control panel. Attach ignitor wire to ignitor (B).

Attach firebox with #10-24x1/2’’machine screws, 5x15 fiber washersand #10-24flange nuts( C ). Push control knobs onto valve stems ( C ).

Burner Assembly

Firebox

A

 

5x15

#10-24

#10-24X1/2”

Fiber Washer Flange Nut

Machine Screw

Qty.10

Qty. 8

Qty.6

 

 

 

 

#10-24x1-1/4”

 

 

Machine Screw

5x15 Fiber Washer

 

Qty.4

#10-24x1-1/4’’Machine Screw

#10-24Flange NutB

 

Heat shield

5x15 Fiber Washer

for tank

 

#10-24x1/2’’Machine Screw

C

#10-24x1/2’’Machine Screw

Valve

Venturi tube

Ignitor wire

5x15 Fiber washer

 

 

Make sure the Venturi tubes are located

 

 

 

underneath Heat Shield

Control Knob

#10-24Flange Nut

22

12 ShelvesAttach mounting brackets to shelf support with side shelf bushing and#8-32x3/8’’ sheet metal screws (A).

Insert mounting bracket into sideburner shelf support, secure with#10-24x1/2’’ machine screws (B).

Attach mounting brackets to front of leg with1/4’’-20x1/2’’ machine screws. Back of leg with1/4’’-20x1-1/4’’ machine screws and1/4’’-20 flange nuts ( C ). Repeat on the sideburner shelf.

 

1/4’’-20x1/2”

1/4’’-20

#8-32x3/8’’

Side Shelf Bushing

#10-24x1/2’’

 

Machine Screw

Flange Nut

Sheet Metal Screw

Qty.4

Machine Screw

 

Qty.4

Qty. 4

Qty.4

 

Qty.4

1/4’’-20x1-1/4"

 

 

 

 

 

Machine Screw

 

 

 

 

 

Qty.4

A

 

 

 

 

Mounting Bracket

B

Side Shelf Bushing

#8-32x3/8’’Sheet Metal Screw

#10-24x1/2’’Machine Screw

C

Side Shelf

1/4’’-20x1/2’’

1/4’’-20x1-1/4’’

Machine Screw

Machine Screw

 

1/4’’-20Flange Nut

23

Sideburner

13 Attach sideburner valve with#8-32x3/8’’ machine screws. Attach sideburner pan with#8-32x3/8’’ sheet metal screws and5x9 fiber washer (A).

Place sideburner into shelf (B).

Make sure valve is inside sideburner tube. Attach sideburner with awing nut. HookSideburner clip to sideburner tube and around manifold. Attach sideburner ignitor wire ( C ) .

Press control knob onto valve stem and sideburner grate onto shelf (D).

#8-32Wing Nut

#8-32X3/8’’

#8-32x3/8’’

5x9 Fiber Washer

Qty.1

Sheet Metal Screw

Machine Screw

Qty.4

 

Qty.3

Qty.2

 

5x9 Fiber Washer

Sideburner

#8-32x3/8’’Sheet Metal Screw

A

B

Sideburner Valve

#8-3/8’’Machine Screw

Correctly assembled burner-to-valveengagement

Sideburner Clip

Sideburner Grate

Qty.1

 

D

C

5x9 Fiber Washer

 

Control Knob

 

Sideburner

 

Sideburner Valve

#8-32Wing Nut

Tube

 

 

Sideburner Clip

 

 

Sideburner Ignitor Wire

24

Lower Hinges

14 Attach lower hinges to back of firebox using#10-24x1/2’’ machine screws,5x15 fiber washers and#10-24 flange nuts. The center flat portion of the hinge should be at the bottom (see inset).

Lower Hinge

#10-24x1/2”

#10-24

5x15

Machine Screw

Flange Nut

Fiber Washer

Qty.4

Qty. 4

Qty.8

 

Center flat portion of

 

 

 

 

 

hinge on bottom

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Lid Handle and Upper Hinges

 

 

15

 

 

Attach handle to lid with 7x15 fiber washersand 1/4’’-20wing nuts.

 

 

Attach upper hinges to back of lid using #10-24x1/2’’machine screws, 5x15 fiber washersand #10-24flange nuts.

 

Hinge should curve downward when properly installed. Do not tighten upper hinge screws.

 

 

 

 

 

 

Handle

 

#10-24X1/2”

#10-24

5x15

 

 

Machine Screw

Flange Nut

Fiber Washer

7x5 Fiber Washer

1/4’’-20Wing Nut

Qty.4

Qty. 4

Qty.8

 

7x15

1/4’’-20

 

Fiber Washer

Wing nut

 

Qty.4

Qty.2

#10-24Flange Nut

 

 

5x15 Fiber Washer

5x15 Fiber Washer

Upper Hinge

#10-24x1/2’’

 

Machine Screw

25

16LidPlace lid assembly onto firebox, aligning hinges. Hinges on lid fit inside hinges on firebox. Secure using twohinge pins andhitch pins. Tighten upper hinge screws.

NOTE: Tighten the hinges screws after installing the hinge pins.

Hinge Pin

Hitch Pin

Qty.2

Qty.2

17

Heat Tent

Place heat tent into firebox. Align the slots on heat tent to heat tent support screws.

Heat Tent

18

Cooking Grate

 

Place grates into firebox.

Cooking Grate

 

 

Hook condiment basket into front panel.

 

 

Condiment basket

26

Swing Away

19 Insert ends of Swing Away pivot wire into holes in sides of grill lid. Insert ends of Swing Away leg wire into holes in sides of firebox. NOTE: Pivot and leg wires, runningside-to-side,should be under wires runningfront-to-back.If pivot and leg wires are on top, swing away is installedupside-down.

Swing Away

Pivot Wire

Leg Wire

20

Grease Cup and Grease Cup Clip

Hang grease cup clip from bottom of firebox and place grease cup into grease clip.

CAUTION

Failure to install grease cup clip and cup will cause hot grease to drip from bottom of grill with risk of fire or property damage.

Grease Cup Clip

Grease Cup

LP Tank

21 LP tank is sold separately. Use only with an OPD(over-fillprotection device) equipped LP tank. Fill and leak check before attaching to grill and regulator.

Tank collar opening must face to front of grill. Loosen wing nut from tank retainer bracket.

Set bottom of tank onto notches in the tank bracket. Place tank retainer bracket onto tank collar and tighten the wing nut.

See Use and Care section to correctly Leak Test and perform the Burner Flame Check.

CAUTION

Cylinder valve must face to front of cart once tank is attached. Failure to install cylinder correctly may allow gas hose to be damaged in operation, resulting in the risk of fire.

Always keep LP cylinders in upright position during use, transport, and storage.

Regulator

LP Tank

LP Cylinder

(not included)

Correctly Installed

LP cylinder

27

EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

Emergencies

Possible Cause

Prevention/Solution

 

 

 

Gas leaking from

• Damaged hose.

• Turn off gas at LP cylinder or at source on natural gas systems. If

cracked/cut/burned

 

anything but burned, replace valve/hose/regulator. If burned,

hose.

 

discontinue use of product until a plumber has investigated cause

 

 

and corrections are made.

Gas leaking from LP

• Mechanical failure due to rusting or

• Replace LP cylinder.

cylinder.

mishandling.

 

Gas leaking from LP

• Failure of cylinder valve from

• Turn off LP cylinder valve. Return LP cylinder to gas supplier.

cylinder valve.

mishandling or mechanical failure.

 

Gas leaking between

• Improper installation, connection not

• Turn off LP cylinder valve. Remove regulator from cylinder and

LP cylinder and

tight, failure of rubber seal.

visually inspect rubber seal for damage. See LP Cylinder Leak Test

regulator connection.

 

and Connecting Regulator to the LP Cylinder.

Fire coming through

• Fire in burner tube section of burner due

• Turn off control knobs and LP cylinder valve. Leave lid open to

control panel.

to blockage.

allow flames to die down. After fire is out and grill is cold, remove

 

 

burner and inspect for spider nests or rust. See Natural Hazard

 

 

and Cleaning the Burner Assembly pages.

Grease fire or

• Too much grease buildup in burner area.

• Turn off control knobs and LP cylinder valve. Leave lid open to

continuous excessive

 

allow flames to die down. After cooling, clean food particles and

flames above cooking

 

excess grease from inside firebox area, grease tray, and other

surface.

 

surfaces.

 

 

 

Troubleshooting

Problem

Possible Cause

Burner(s) will not light

GAS ISSUES:

• Trying to light wrong burner.

using ignitor.

• Burner not engaged with control valve.

(See Electronic Ignition

Troubleshooting also)

• Obstruction in burner.

 

Continued on next page.

No gas flow.

Vapor lock at coupling nut to LP cylinder.

Coupling nut and LP cylinder valve not fully connected.

ELECTRICAL ISSUES:

Electrode cracked or broken; “sparks at crack.”

Electrode tip not in proper position.

Wire and/or electrode covered with cooking residue.

Wires are loose or disconnected.

Wires are shorting (sparking) between ignitor and electrode.

Prevention/Solution

See instructions on control panel and in Use and Care section.

Make sure valves are positioned inside of burner tubes.

Ensure burner tubes are not obstructed with spider webs or other matter. See cleaning section of Use and Care.

Make sure LP cylinder is not empty. If LP cylinder is not empty, refer to “Sudden drop in gas flow.”

Turn off knobs and disconnect coupling nut from LP cylinder. Reconnect and retry.

Turn the coupling nut approximately one-halftothree-quartersadditional turn until solid stop. Tighten by hand only - do not use tools.

Replace electrode(s).

Main Burners:

Tip of electrode should be pointing toward gas port opening on burner. The distance should be 1/8” to 1/4”. Adjust if necessary.

Sideburner:

Tip of electrode should be pointing toward gas port opening on burner. the distance should be 1/8” to 3/16”. Adjust if necessary.

Clean wire and/or electrode with rubbing alcohol and clean swab.

Reconnect wires or replace electrode/wire assembly.

Replace ignitor wire/electrode assembly.

28

Troubleshooting (continued)

Problem

Possible Cause

Prevention/Solution

 

 

 

Burner(s) will not light

ELECTRONIC IGNITION:

• See Section I of Electronic Ignition System.

using ignitor.

• No spark, no ignition noise.

(See Electronic Ignition

• No spark, some ignition noise.

• See Section II of Electronic Ignition System.

Troubleshooting also)

 

• Sparks, but not at electrode or at full

• See Section III of Electronic Ignition System.

 

strength.

 

 

PIEZO PUSH-BUTTONAND ROTARY:

• Replace ignitor.

 

Push-buttonsticks at bottom.

 

• Rotary knob rotates without clicking.

• Replace knob.

 

• Sparking between ignitor and electrode.

• Inspect wire insulation and proper connection. Replace wires if

 

 

insulation is broken.

 

 

 

Burner(s) will not

• See “GAS ISSUES:” on previous page.

 

match light.

• Match will not reach.

• Use long-stemmatch (fireplace match).

 

 

• Improper method of match-lighting.

• See “Match-Lighting”section of Use and Care.

 

 

 

Sudden drop in gas

• Out of gas.

• Check for gas in LP cylinder.

flow or low flame.

• Excess flow valve tripped.

• Turn off knobs, wait 30 seconds and light grill. If flames are still low,

 

 

 

turn off knobs and LP cylinder valve. Disconnect regulator.

 

 

Reconnect regulator and leak-test.Turn on LP cylinder valve, wait

 

 

30 seconds and then light grill.

 

• Vapor lock at coupling nut/LP cylinder

• Turn off knobs and LP cylinder valve. Disconnect coupling nut from

 

connection.

cylinder. Reconnect and retry.

 

 

 

Flames blow out.

• High or gusting winds.

• Turn front of grill to face wind or increase flame height.

 

• Low on LP gas.

• Refill LP cylinder.

 

• Excess flow valve tripped.

• Refer to “Sudden drop in gas flow” above.

 

 

 

Flare-up.

• Grease buildup.

• Clean burners and inside of grill/firebox.

 

• Excessive fat in meat.

• Trim fat from meat before grilling.

 

• Excessive cooking temperature.

• Adjust (lower) temperature accordingly.

 

 

 

Persistent grease fire.

• Grease trapped by food buildup around

• Turn knobs to OFF. Turn gas off at LP cylinder. Leave lid in position

 

burner system.

and let fire burn out. After grill cools, remove and clean all parts.

 

 

 

Flashback...

• Burner and/or burner tubes are blocked.

• Turn knobs to OFF. Clean burner and/or burner tubes. See burner

(fire in burner tube(s)).

 

cleaning section of Use and Care.

 

 

 

Unable to fill LP

• Some dealers have older fill nozzles

• The worn nozzles don’t have enough “bite” to engage the valve. Try

cylinder.

with worn threads.

a second LP dealer.

 

 

 

One burner does not

• Grease buildup or food particles in

• Clean carry-overtube(s) with wire brush.

light from other

end(s) of carryover tube(s).

 

burner(s).

 

 

 

 

 

29

NOTES

30

Warranty Registration Department

P.O. Box 1240

Columbus, GA 31902-1240

31