Char-Broil 463741209 User Manual

8.69 Mb
Rev. 04 • 08-19-08 • 80012036


MODEL 463741209

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: 45 minutes

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-25

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27

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 cylinder under or near the appliance or in an enclosed area.

Never fill a cylinder beyond 80% full.

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

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 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.



For Safe Use Of Your Grill And To Avoid Serious


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 in well-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.

sNever move grill while in operation or still hot. Uselong-handledbarbecue utensils and oven mitts to avoid

burns and splatters.

sMaximum load for sideburner and side shelf is 10 lbs. greaseThe cup must be attached to grease cup 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.

sKeep ventilation openings in cylinder enclosure (grill cart) free and clear of debris.

sDo not store objects or materials inside the grill cart enclosure that would block the flow of combustion air to the underside of either the control panel or the firebox bowl.

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

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!


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 cylinder off.

Do not leave grill unattended while preheating or burning off food residue on HI. If grill has not been regularly cleaned, a grease fire can occur that may damage the product.

Ignitor Lighting

sDo not lean over grill while lighting.

1.Turn all burner control valves.

2.Turn on gas source or tank.

3.Open lid during lighting.

4.To ignite, turn IGNITION BURNER knob to PRE-HEAT.

5.Push IGNITOR button rapidly.

6.If ignition does NOT occur in 5 seconds, turn the burner

controls , wait 5 minutes and repeat the lighting procedure.

7.To ignite right burner, turn right knob to PRE-HEAT.

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

Lighting instructions continued on next page.



Turn controls and gas source or tank OFF when not in use.


If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure. If the burner does not ignite with the valve open, gas will continue to flow out of the burner and could accidently ignite with risk of injury.


sDo not lean over grill while lighting.

1.Turn all burner control valves.Open lid during lighting. Turn on gas at LP cylinder.

2.Place lit match into match holder, then into side of grill bottom (as shown below).

3.Push in and turn IGNITION BURNER knob to PRE-HEAT.Be sure burner lights and stays lit.

4.To ignite right burner, turn right knob to PRE-HEAT.

After Lighting: Turn knobs to HI for warm-up.

Burner Flame Check

Light burner, rotate knobs from HIGH to LOW. You should see a smaller flame in LOW position than seen on HIGH. Always check flame prior to each use. If only low flame is seen refer to "Sudden drop or low flame" in the Troubleshooting Section.



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.





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 LOposition then turn back to OFFposition. Valves should turn smoothly.


Turn gas off at control knobs and LP cylinder.
Remove cooking grate and heat tent.
Under grill remove grease cup, disconnect ignitor wire from burner.
Inside grill remove burner assembly (A), clean ceramic portion of electrode with rubbing alcohol and a swab. 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.
If grill is to be stored, coat burner lightly with cooking oil. Wrap in protective cover to keep insects out.
If not storing grill after cleaning, replace burner into grill bottom.



Cleaning the Burner Assembly

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










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 venturis.















VERY IMPORTANT: Burner tubes must re-engagevalve

openings. See illustration (A).

8.Reattach ignitor wire to electrode.

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

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

“Burner Flame Check”.

In some areas of the country, spiders or small insects have been

known to create “flashback” problems. The spiders spin webs, build

Correct burner-to-valveengagement

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.



Burner Tube






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


1 Year from date of purchase*

Perforation, Manufacturing, and





Materials Defects Only






*Note: A dated sales receipt 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.


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.


Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. 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.


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 forth 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-purchaser prior 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.

























































































































































(A)Place leg shelf support onto leg with leg extender. Attach each side with #10-24x1-3/4" machine screw and

1#10-24"wing nut.

(B)Attach one support bar to legs with #10-24x1-3/4"machine screwsand #10-24wing nuts.

NOTE: Do not tighten screws until Step 5.

Leg Shelf Support


Support Bar


#10-24x1-3/4"Machine Screw

Qty. 6 Right leg

Pay attention to the orientation of

Right Leg during assembly

#10-24Wing Nut Qty. 6


(A) Place the leg shelf support with match holder onto leg as shown. Attach another leg support to other leg with no leg

extender. Attach each side with #10-24x1-3/4"machine screwand #10-24"wing nut.

(B) Attach one support bar to the upper part of leg with#10-24x1-3/4" machine screws and#10-24 wing nuts.

NOTE: Do not tighten screws until Step 5.

Leg Shelf Support

Support Bar


Match Holder






Machine Screw


Qty. 6



Left leg


Pay attention to the

orientation of Right Leg

Wing Nut

during assembly

Qty. 6




Right leg, place support bar between legs, and place two rails on outside of leg. Attach with #10-24x1-3/4" machine screws

and #10-24 wing nuts. On left leg attach rail as shown.

Right leg

Place rail with rating label to back.

Support Bar



Machine Screw Qty. 8

#10-24Wing Nut Qty. 8

Turn assembly upside-down.Insert axle bolts into wheels. Facing the back, position tank support bracket between left legs.4 Insert axle bolt through leg and bracket and secure with hitch pin.

Axle bolts



Tank support bracket

1” Hitch Pin

Qty. 2

Hitch Pin

“Cone” side of wheel against leg.

5/16” Axle Bolt Qty. 2



(A) Place front panel with holes side on top, attach to front of cart with#10-24x1/2" machine screws in lower holes and with

push fasteners in upper holes.

(B) You will need to remove the wing nuts and screws installed instep 1A to attach another front panel. And usepush fasteners to attach the front panel on the lower holes.Tighten all screws from previous steps.

Holes on top

Push Fastener

Upper hole

#10-24X1/2"Machine Screw

Lower hole



#10-24X1-3/4”Machine Screw

Push Fastener


Qty. 4

Machine Screw


Qty. 2


Wing nut





Hook the tank exclusion wires onto back of front panels and rear rail as shown.

Secure with #10-24x1/2”screws and#10-24wing nuts.



Machine Screw

Wing Nut

Qty. 2

Qty. 2

Tank exclusion


#10-24X1/2”Machine Screw

Wing nut


(A) Attach control panel to cart with #10-24x1-3/4"machine screwsand #10-24wing nuts.

7 (B) Place valve/hose/regulator onto control panel. Attach withtwo #10-24x1/2" machine screws. (Note: Make sure the two valve stems are leveled; otherwise, this can cause main burner level problems.) Insert ignitor into control panel. Insert the round terminal plug of the ignitor wire into the pin located at the end of the ignitor.

Control panel


#10-24x1-3/4"Machine Screw Qty. 2



Wing Nut


Qty. 2



#10-24X1/2"Machine Screw Qty. 2




(A) Place firebox onto cart. Attach with #10-24x1-1/4"carriage bolt, 7mm ID, 16mm OD fiberwashersand#10-24wingnut.



(B) Position heat shield as shown. Place burner assembly into firebox. Make sure venturi tubes and valves are correctly



engaged. Place small end of venturi clipinto venturi tube and large part of clip around valve. If burner is not leveled from left to


right, adjust the two screws attaching valveto control panel in step 8B. Place control knobs on valves as shown in figure (A).


Place heat shield onto burner venturi tube, then insert burner/ heat shield through venturi holes on firebox. Make sure ignitor


wire go through the hole on heat shield and firebox as shown.



(C) Inside firebox, attach firebox and control panel with 5mm ID, 16mm OD fiber washers and#8 sheet metal screws



(D)Attach ignitor wire to electrode.

Heat Shield

Correctly assembled valve in burner tube and venturi clips


V a l v e


Venturi tube









Carriage Bolt

Qty. 4

Venturi clip








#8 Sheet Metal








Wing Nut


Fiber washer









Qty. 4


Qty. 2

Qty. 2











#8 Sheet







Metal Screw




Fiber Washer










Qty. 4







Fiber washer











Control knobs







Heat shield


Venturi clip













Qty. 2


Ignitor wire D

































Attach side shelves with #10-24x1-3/4"machine screws.






Right side

Left side


Machine Screw


Qty. 8




Attach lower lid hinges to back of firebox using two 1/4-20x1/2” machine screws,7mm ID, 16mm OD fiber washers, and

1/4-20 Flange nuts per hinge. The center flat portion of the hinge should be at the bottom (see inset below).




Flange Nut

Fiber Washer

Machine Screw

Qty. 4

Qty. 4

Qty. 4

Center flat portion

Lower lid


of hinge on bottom.






Attach handle to front of lid using two insulation washers,fiber washers and

11 back of lid using two 1/4-20x1/2”machine screws, 7mm ID, 16mm OD fiber

Hinges should curve downward when properly installed.

#10-24 wing nuts. Attach upper lid hinges towashers, and1/4-20 flange nuts per hinge.


Insulation Washer


Insulation Washer


Machine Screw

Qty. 2


Qty. 4







Fiber Washer



Qty. 2


Fiber Washer



Qty. 4





Wing Nut



Qty. 2

7mm ID, 16mm OD





Fiber Washer





Flange Nut



Qty. 4



5mm ID, 16mm OD

Fiber Washers

Upper lid hinge


Place lid assembly onto firebox, aligning hinges. Hinges on lid fit inside hinges on firebox. Secure using two hinge pins and

12 hitch pins.

1” Hitch Pin

Qty. 2

Hinge Pin

Qty. 2

13 Place vaporiser bar ontoV-shapedbar rests inside firebox. Place cooking grate onto firebox.

NOTE: The vaporiser bar must be inserted into firebox at an angle in order to fit beneath

cooking grate supports.

Cooking grate

Vaporiser bar


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 14 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 installed upside-down.

Pivot Wire

Swing Away

Leg Wire

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


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


16 Insert tank wire into left legs. Rotate tank wireinward toward cart.

Tank collar opening must face to front of grill (A). Set bottom of tank into notches of tank bracket(B). Lean tank inward and17 engage tank collar with tank wire(C).

LP CYLINDER IS SOLD SEPARATELY. Fill and leak check the cylinder before attaching to grill and regulator (see Use & Care section). Once cylinder has been filled and leak checked, place cylinder into notches in tank support bracket.Make

sure cylinder valve is facing front of grill. See Use & Care section of this manual to perform the “Burner

Flame Check” and for important safety instructions before using.

Tank Collar

Curved portion

of tank wire




Correctly Installed

LP cylinder.

Always keep LP cylinders in

upright position during use,

transport, and storage.



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.


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


Possible Cause





Gas leaking from

• Damaged hose.

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



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



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.




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









Possible Cause

Burner(s) will not light


• 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.


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.


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.


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.

• Dead battery.

• Replace with a new AA-sizealkaline battery.


Troubleshooting (continued)


Possible Cause





Burner(s) will not light


• 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.






• 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



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.





• 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.





• 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


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).