Char-Broil 5101194 User Manual

2.98 Mb





To installer or assembler:

Leave this manual with consumer for future reference.

To consumer:

Keep this manual for future reference.




If you smell gas:

California Proposition 65


Shut off gas to the appliance.

Combustion by-productsproduced when


Extinguish any open flame.

using this product contain chemicals




Open lid.

known to the State of California to cause


If odor continues, keep away from the appliance and

cancer, birth defects, or other


immediately call your gas supplier or your fire department.

reproductive harm.



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

Improper installation, adjustment,

alteration, service or maintenance can

vapors in the vicinity of this or any other appliance.

cause injury or property damage. Read the


2. An LP cylinder not connected for use shall not be stored in

installation, operating and maintenance

instructions thoroughly before installing

the vicinity of this or any other appliance.

or servicing this equipment.


If you have any questions or need assistance during assembly, please call 1-800-232-3398.

To insure your satisfaction and for follow-up service, register your product online at

05101194 • 42804116 • 07-14-05

Use and Care

Safety Symbols

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


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


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

Char-Broil®Outdoor Stove Top

Thank you for your purchase. The Outdoor Stove Top was designed to take the cooking of many of you favorite foods from your INDOOR stove top TO THE OUTDOORS. The Outdoor Stove Top can use many of your indoor stock pots, griddles, and woks. Also, look for cooking accessories from Char-Broilat the store where you purchased the Outdoor Stove Top.


Never use a cooking pot or vessel larger than 12 quarts or 12.5” in diameter.

Read and follow the instructions included with any cooking accessory before using with this appliance.


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

Installation Safety Precautions

Use appliance only with LP (propane) gas and the regulator/valve assembly supplied.

Appliance installation must conform with local codes, or in their absence with National Fuel Gas Code, NFPA 54 / ANSI Z223.1. Handling and storage of LP cylinders must conform to LP Gas CodeNFPA/ANSI 58. Appliance is not for use in or on recreational vehicles and/or boats.

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

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

This appliance is safety certified for use in the United States only. Do not modify for use in any other location. Modification will result in a safety hazard.


Some parts may contain sharp edges. Wear protective gloves if necessary.


NEVER USE THIS APPLIANCE AS A TURKEY FRYER! Use as a turkey fryer may result in a hazardous situation causing property damage, personal injury, or loss of life.

Limited Warranty

The manufacturer warrants the product for replacement or repair of parts and/or workmanship for a period of 90 days. Paint is not warranted and will require touchup.

These limited warranties are made exclusively to the original customer presenting proof of purchase. These warranties are limited to non-commercialresidential use only. Any returned goods must be shipped prepaid. These warranties do not cover normal wear and tear or damages resulting from abuse or misuse. This warranty excludes incidental or consequential cost due to damages or losses or property of any nature.

NOTICE: Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other legal rights which may vary from state to state.

For further information, contact the manufacturer, toll free at 1-800-232-3398.


Table of Contents

Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Safety Precautions . . . . . . . . . . . . . . . . . . . 2

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

LP Cylinder Removal, Transport, and Storage . . . . . . . 4

LP Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

LP (Liquefied Petroleum Gas) . . . . . . . . . . . . . . . . . . . 4

LP Cylinder Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

LP Cylinder Exchange . . . . . . . . . . . . . . . . . . . . . . . . . 5

LP Cylinder Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . 5

Connecting Regulator to the LP Cylinder . . . . . . . . . 5-6

Leak Testing Valve, Hose, and Regulator. . . . . . . . . . . 6

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ignitor Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Match Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Burner Flame Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Burner Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Turning Appliance Off . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ignitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Valve Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Hose Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Natural Hazard • Spiders . . . . . . . . . . . . . . . . . . . . . . . 8

Care and Cleaning of Stainless Steel. . . . . . . . . . . . . . 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

To insure your satisfaction and for follow-upservice, register your product online at:



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 control knob and LP cylinder valve. Turn coupling nut counterclockwise by hand only - do not use tools to disconnect. 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.

LP Cylinder









A disconnected LP cylinder in 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 patio or other building. Never leave an LP cylinder inside a vehicle which may become overheated by the sun.

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

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

Storage of appliance indoors is permissible only if the cylinder is disconnected and removed from the appliance.

LP Cylinder

The LP cylinder used with your Outdoor Stove Top must meet the following requirements:

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

Be constructed and marked in accordance with specifications for LP cylinder of the U.S. Department of Transportation (DOT). See LP cylinder collar for marking.

LP cylinder valve must have:

Type 1 outlet compatible with regulator.

Safety relief valve.

UL listed Overfill Protection Device (OPD). This OPD safety feature is identified by a

unique triangular hand wheel. Use only cylinders equipped with this type of valve.

LP cylinder must be arranged for vapor withdrawal and include collar to protect LP cylinder valve.

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 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 Cylinder Exchange

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 appliance.

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.

Appliance must be leak checked outdoors in a well ventilated area, away from ignition sources such as gas fired or electrical appliances. During leak test, keep appliance away from open flames or sparks.

Use a clean paint brush and 50/50 soap and water solution. Use mild soap and water. Do not use Household cleaning agents. Damage to gas train components can result.

Brush soapy solution onto the shaded areas.


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

Connecting Regulator To The LP Cylinder

1.LP cylinder must be properly secured onto appliance.

2.Turn control knob to OFF position.

3.Turn LP cylinder OFF by turning hand-wheelclockwise to a full stop.

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


f Clockwis











OPD Hand Wheel

Safety Relief


Type 1 outlet with




thread on outside



Strap and Cap



Do not use a POL transport plug (A)


(plastic part with external threads)! It


will defeat the safety feature of the






5.Hold regulator, insert nipple (B) into LP cylinder valve. Hand tighten coupling nut, holding regulator in a straight line (C) with LP cylinder valve so as not to cross thread the connection.

Nipple has to be centered into the LP cylinder valve.





Hold coupling nut and regulator


as shown for proper connection





to LP cylinder valve.



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


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



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

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


Do not use appliance until leak checked.

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

If you cannot stop a gas leak, immediately close LP cylinder valve and call a LP gas

supplier or your fire department!

Leak Testing Valve, Hose and Regulator

1.Turn control knob to OFF.

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

3.Completely open LP cylinder valve by turning hand wheel counter clockwise. 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 on areas where bubbles are shown.

5.“If growing” bubbles appear, there is a leak. Close LP cylinder valve immediately andre-tightenconnections.If leaks cannot be stopped “do not try to repair”. Call for replacement parts. Order new parts by giving the part number from the parts list to the Service Center at1-800-232-3398.

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

Safety Tips

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

When appliance is not in use, turn off control knob and LP cylinder valve.

Never move appliance while in operation or still hot.

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

Check appliance before each use for buildup of any leaves or other material that will burn or block the burner ports. Clean when needed before using. Have appliance inspected annually by a qualified service person.



For Safe Use of Your Outdoor Stove Top and to Avoid Serious Injury:

Do not let children operate or play near appliance.

Keep appliance area clear and free from materials that burn.

Do not block holes in sides or back of appliance.

Check burner flames regularly.

Use appliance only in a 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 appliance. (Unless briquets are supplied with your appliance.)

Use appliance 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 appliance 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 appliance is hazardous.

Never operate appliance with LP cylinder out of correct position specified in assembly instructions.

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

Ignitor Lighting

1.Open lid during lighting.

2.Press and turn the control knob to the HI position.

3.Turn ROTARY IGNITOR knob rapidly.

4.If ignition does not occur in 5 seconds, turn the burner control knob OFF, wait 5 minutes, and repeat lighting procedure. If ignition still does not occur, follow“Match Lighting” instructions.


If burner does not light turn knob to OFF, wait 5 minutes, try again. If the burner does not ignite with valve open, gas will continue to flow out of the burner and could accidentally ignite with risk of injury.

Match Lighting

Do not lean over appliance while lighting. Use a large kitchen match or fireplace match to light the appliance.

1. Place a lit match to burner.

2.Press and turn control knob To HI.

Burner Flame Check


• Light burner, rotate knob


from HI toLOW. You


should see a smaller

flame in LOW position

than seen on HI. Always check flame prior to each use.

Burner Check

Inspect burner prior to each use. If burner is damaged do not use. Call manufacturer at 1-800-232-3398to obtain a replacement.

Turning Appliance Off

Turn knob to OFF position. Turn LP cylinderOFF by turning handwheel clockwise to a full stop.

Ignitor Check

Turn gas OFF at LP cylinder. Turn ignitor knob rapidly. “Click” should be heard and spark seen each time between burner and electrode. See “Troubleshooting” if no click or spark.

Valve Check

Important: Make sure gas is OFF at LP cylinder before checking valves. Knob locks inOFF position. To check valve, first push in knob and release, knob should spring back. If knob does not spring back, replace valve assembly before using appliance. Turn knob toMED position then turn back toOFF position. Valve should turn smoothly.

Hose Check

Before each use, check to see if hose is cut or worn. Replace damaged hose before using appliance. Use only hose/valve/regulator specified by manufacturer.



Natural Hazard • Spiders

FACT: Sometimes spiders and othersmall insects climb into the burner tube.The spiders spin webs, build nests andlay eggs. The webs or nests can be verysmall, but they are very strong and can

block the flow of gas. Clean burner prior to use after storing, or after a period of one Month not being used.

Typical spider webs inside burner

An obstruction can result in a “flashback” (a fire in the burner tube). The appliance may still light, but the obstruction does not allow full gas flow to the burner.

If you experience the following:

1.Smell gas.

2.Burner will not light.

3.Fire coming from around or behind control knob.

STOP! Immediately turn off gas at LP cylinder.

SOLUTION: Wait for appliance to cool.

Clean burner often. Spiders and insects don’t care if your appliance is brand newor you just cleaned it. Use a hose with anozzle attached. Forced water will wash

out the web.


For residential use only. Do not use for commercial cooking.

General Cleaning

Do not mistake brown or black accumulation of grease and smoke for paint. Interiors of gas appliances 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 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.

Stainless steel surfaces: To maintain your appliance’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 grate: Coating the cooking grate withspray-oncooking oil will keep the food from sticking and make clean up easier. After cooking, scrape the grates with a long handled, brass wire bristle brush.



Extreme temperatures from charcoal or wood fires will cause discoloration of stainless steel surfaces. Routine cleaning is necessary to preserve the appearance and corrosion resistance of Stainless Steel. The methods below are suggestions for cleaning stainless steel surfaces. Choose a cleaning method appropriate to the requirement. If you choose to use scouring powder or solvents, consult with the solvent manufacturer or supplier before use.

Before cleaning, first test any cleaning product in an inconspicuous location and consider the possibility of scratching and the potential for corrosion caused by not completely removing cleaners. Never use brushes or steel wool as they will scratch and leave particles embedded on stainless steel surfaces, which can lead to rusting. Always rub or wipe in the direction of the polish lines in the stainless steel surface, not across them. Thorough rinsing with clean water is recommended after all cleaning procedures. Dry all surfaces completely after rinsing. Be careful not to let any stainless steel cleaner come in contact with painted or plastic components as damage may occur.

Routine Care

The Char-Broil®Stainless Steel Grill Cleaner and the Thermos® Stainless Steel Grill Cleaner are good choices for routine cleaning of stainless steel surfaces. Mild stains and loose dirt and soil can also be removed with a soft cloth and clean warm water. Rinse with clean water and wipe dry.

Stubborn Stains

Stubborn stains, discoloration and possibly rust and rust pitting can occur from cooking, exposure to harsh outdoor conditions, or extreme cooking temperatures. There are many cleaning agents commercially available formulated to restore the finish of stainless steel. Obtain advice from the solvent manufacturer or supplier when choosing the appropriate cleaner for your requirement. These cleaners can be acidic. Care should be taken to avoid contact with eyes or mouth. Be careful not let any powder or solvent come in contact with painted or plastic components as damage may occur.

The chart below has been reproduced with permission from the Specialty Steel Institute of North America. For additional details regarding the care and cleaning of stainless steel, visit their website at for more information. For the latest new products for the care and cleaning of stainless steel go to


Cleaning Agents*


Routine Cleaning

Warm Water, Soap, Ammonia, Detergent

Apply with sponge or soft cloth.



Can be used on all finishes.




Fingerprints and Smears

3M Stainless Steel Cleaner and Polish, Arcal 20, Lac-O-Nu,

Provides barrier film to minimize


Lumin Wash, O’Cedar Cream Polish, Stainless Shine

fingerprints. Can be used on all finishes.

Stubborn Stains

3M Stainless Steel Cleaner and Polish, All chem Concentrated

and Discoloration

Cleaner, Samae, Twinkle, Cameo Copper Cleaner, Grade FFF


or Grade F Italian Pumice, Whiting or Talc, Liquid Nu Steel,


Copper’s or Revere Stainless Steel Cleaner, Household


Cleaners, Lumin Cleaner, Zud Restoro, Sta-Clean,Highlite,


Allen Polish, Penny-Brite,Copper-Brite

Rub lightly, using dry damp cloth, in the direction of polish lines on the stainless steel.

Grease and Blood Burnt-onorBaked-onFoods

Scotch-BritePower Pad 2001,Easy-Off,De-Grease-It,4% to 6% hot solution of such agents astri-sodiumpolyphosphate, 5% to 15% caustic soda solution

Excellent removal on acids, all finishes. Particularly useful where rubbing

is not practical.

Grease and Oil

Any good commercial detergent or caustic cleanser.

Apply with sponge or soft cloth in direction of polish lines.

*NOTE: Use of proprietary names is intended only to indicate a type of cleaner and does not constitute an endorsement. Omission of any proprietary cleanser does not imply its inadequacy. All products should be used in strict accordance with instructions on package.




Possible Cause


Burner will not light

Electrode and burner are wet.

— Wipe dry with cloth.

using ignitor.

Electrode is cracked or broken,

Replace electrode.



“sparks at crack”.




— Wire is loose or disconnected.

— Reconnect or replace ignitor wire.


— Wire is shorting (sparking)

Replace ignitor wire.



between ignitor and electrode.




Bad ignitor.

Replace ignitor.

Burner will not match-

No gas flow.

— Check to see if LP cylinder is empty. If LP cylinder is





not empty, refer to “Sudden drop in gas flow”.


— Coupling nut and regulator not

— Turn the coupling nut about one-halfto three quarters



fully connected.


additional turn until solid stop. Tighten by hand only—





do not use tools.


— Obstruction of gas flow.

Clear burner tube.


— Disengagement of burner to

Re-engageburner and valve.







Is appliance assembled

Check assembly instruction steps.






Sudden drop in gas

Out of gas.

— Check for gas in LP cylinder.

flow or low flame.

Excess flow valve tripped.

— Turn off knob, wait 30 seconds and light appliance. If





flames are still low, turn off knob and LP cylinder





valve. Disconnect regulator. Reconnect regulator and





leak check. Turn on LP cylinder valve, wait 30





seconds and then light appliance.

Flames blow out.

High or gusting winds.

Increase flame height.


— Low on LP gas

Refill LP cylinder.


— Excess flow valve tripped.

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

Flashback... (fire in

Burner is blocked.

Turn knob to OFF and clean burner.

burner tube).





Unable to fill LP

Some dealers have older fill

— The worn nozzles don’t have enough “bite” to engage



nozzles with worn threads.


the valve. Try a second LP dealer.