Char-Broil COMMERICAL 463248708 User Manual

6.3 Mb




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

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


Leave this manual with consumer.


Keep this manual for future reference.


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

If you have questions or need assistance during assembly, please call 1-888-430-7870.

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

463248708 • 80016375 • 03-27-08


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.

Call Grill Service Center for Help and Parts

If you need assistance with your product or warranty parts call

1-888-430-7870.Hours of Service Center Operation are 8:00 A.M. To 6:00 P.M. EST Monday - Friday.

To order non-warrantyreplacement parts or accessories please visit us on the web or call1-888-430-7870and one of our friendly and knowledgeable agents will be glad to assist you.

IMPORTANT: Fill out the product record information below.

Model Number

Serial Number

See rating label on grill for serial number.

Date Purchased


For residential use only. Do not use for commercial


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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. 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 only. Do not modify for use in any other location. Modification will result in a safety hazard.

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 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.


For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Grill Service Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

Use and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-26

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

To insure your satisfaction

and for follow-upservice,

register your grill

online at:


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.

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Retainer Strap
Safety Cap
LP Cylinder Valve



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

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 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). 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 (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.

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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 grill.

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 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.

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


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

cylinder. Contact an LP gas supplier or your fire


Connecting Regulator to the LP Cylinder

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 turning hand-wheelclockwise to afull stop.

4.Remove the protective cap from LP cylinder 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 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.

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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. Order new parts by giving the serial, model number and name and part number of items needed (see parts list) to the Grill Service Center at1-888-430-7870.

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

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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 sides 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 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.

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 tray must be inserted into grill and emptied after

each use. Do not remove grease tray 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.

Main Burner Ignitor Lighting

sDo not lean over grill while lighting.

1.TurnOFF all Gas Burner Control Valves.

2.Turn ON gas source or tank.

3.Open lid during Lighting.

4. To ignite turn burner control valve to


5.Once burner has ignited (use flame viewing ports on front of control panel to verify ignition), turn knob to desired setting.

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

7.Ignite remaining burners by repeating steps 4 through 6

for each burner.

Lighting instructions continued on next page.

463248708 • 7


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 OFF all burner control valves.

2.Open lid. Turn on gas at LP cylinder.

3.Place lit match into match holder (hanging from cart side panel), then into lighting hole on right or left side of grill.

4.Push in and turn far right or far left burner knob to HIGH . Be sure burner lights and stays lit.

5.Light adjacent burners in sequence by pushing knobs in and turning to HIGH .

Sideburner Ignitor Lighting

sDo not lean over grill while lighting.

1.Turn OFF all gas burner control valves.

2.Turn ON gas source or tank.

3.To ignite SIDEBURNER, open sideburner cover.

4.Turn sideburner knob to , to ignite burner.

5.Once burner has ignited turn knob to desired setting.

6.If sideburner does NOT light, turn knob to OFF, wait 5 minutes, then repeat lighting procedure.

WARNING: Only use griddle accessory while the control knob is set to GRIDDLE.

Warning:Sideburner Match Lighting

1.Open sideburner lid. Turn on gas at LP cylinder.

2.Place lit match near burner.

3. Turn sideburner knob to HIGH. Be sure burner lights and

stays lit.

Burner Flame Check

Remove cooking grates and flame tamers. Light burners, rotate knobs from HIGHto LOW. You should see a smaller flame in LOW position than seen on HIGH. Perform burner

flame check on sideburner, also. Always check flame prior to each use. If only low flame is seen refer to "Sudden drop or low flame" in the Troubleshooting Section.



Turning Grill Off

Turn all knobs to OFF position. Turn LP cylinder off by turninghand-wheelclockwise to a full stop.

Ignitor Check

Turn gas off at LP cylinder. Press and hold electronic ignitor button. "Click" should be heard and spark seen each time between collector box or burner and electrode. See

"Troubleshooting" if no click or spark.

Valve Check

Important: Make sure gas is off at LP cylinder 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.

Hose Check

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

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. useDo not 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 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.

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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.






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.

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.

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 grates and flame tamers.

3.Remove screws and carryover tubes from rear of burners.

4.Remove screw and washers to disengage burner from bracket on firebox.

5.Remove screws to detach electrode from burner. Electrode should remain in firebox.

6.Carefully lift each burner up and away from valve openings.

We suggest three ways to clean the burner tubes. Use the one easiest for you.

(A)Bend a stiff wire (a light weight coat hanger works well) into a small hook. Run the hook through each burner tube several times.

(B)Use a narrow bottle brush with a flexible handle (do not use a brass wire brush), run the brush through each burner tube several times.

(C)Wear eye protection: Use an air hose to force air into the burner tube and out the burner ports. Check each port to make sure air comes out each hole.

7.Wire brush entire outer surface of burner to remove food residue and dirt.

8.Clean any blocked ports with a stiff wire such as an open paper clip.

9.Check burner for damage, due to normal wear and corrosion some holes may become enlarged. If any large cracks or holes are found replace burner.

VERY IMPORTANT: Burner tubes must reengage valve

openings. See illustrations at right.

10.Attach electrode to burner.

11.Carefully replace burners.

12.Attach burners to brackets on firebox.

13.Reposition carryover tubes and attach to burners. Replace flame tamers and cooking grates.




















































burner bracket

463248708 • 9

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 and poultry.

Separate: Separate raw meats and poultry fromready-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.

For more information call: USDA Meat and Poultry Hotline at 1-800-535-4555In Washington, DC (202)720-3333,10:00 am- 4:00 pm EST.

How To Tell If Meat Is Grilled Thoroughly

Meat and poultry cooked on a grill often browns very fast on the outside. Use a meat thermometer to be sure food has reached a safe internal temperature, and cut into food to check for visual signs of doneness.

Whole poultry should reach 180° F; breasts, 170° F. Juices should run clear and flesh should not be pink.

Hamburgers made of any ground meat or poultry should reach 160° F, and be brown in the middle with no pink juices. Beef, veal and lamb steaks, roasts and chops can be cooked to 145° F. All cuts of pork should reach 160° F.

NEVER partially grill meat or poultry and finish cooking later. Cook food completely to destroy harmful bacteria.

When reheating takeout foods or fully cooked meats like hot dogs, grill to 165° F, or until steaming hot.


Using pots larger than 6 quarts in capacity could exceed weight limit of the

sideburner shelf, resulting in failure of grill cart components.

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