Char-Broil The Big Easy 42804468 User Manual

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Smoker, Roaster & Grill

Product Guide

Model 10101550

IMPORTANT: Fill out the product record information below.

Serial Number

See rating label on unit for serial number.

Date Purchased

Estimated Assembly Time: 1 Hour

FOR OUTDOOR USE ONLY

CAUTION:WARNING:

Read and follow all warnings and instructions before assembling and using the appliance.

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

INSTALLER/ASSEMBLER:

Leave this manual with consumer.

CONSUMER:

Keep this manual for future reference.

CAUTION:

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 1-800-241-7548.

To insure your satisfaction and for follow-upservice, register your appliance online atwww.charbroil.com/register

The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Caldera®; Charcoal2Go®; Char-Broil®;America's Legendary Barbeque Company®; American Gourmet®; Bandera®; Brush Hawg®; CB 940®;Char-Diamonds®;Char-BroilCharcoal/Gas®; Everybody Grills®; Everybody Outside®; FastStart®; Grill 2 Go®; Grill 2 Go® Express®; Grill Lovers®; Infrared Grilling That’s All About U®; Keepers of the Flame®; New Braunfels

Smoker Company®; Patio Bistro®; Patio Caddie®; Patio Kitchen®; Pro-Sear®;RED®; Quantum®; Santa Fe®; Sear and Grill®; Sierra®; Signature Series®;

Sure2Burn®; The Big Easy®; Trentino®; U®; Wild West Tradition®; and the following marks:

® ®

The following are trademarks of W.C. Bradley Co.: Advantage Series™; Auto-Clean™;ChefTested™; Commercial Series™; Designer Series™;; Diamond

Flame™; Double Chef™; Fireball™; Firenzy™; FlavorMaster™;Front Avenue™; Grill 2 Go® Advantage™; Hog and Yard Bird™; H20 Smoker™; Infrared.

Grilling’s Juicy Little Secret™; Incredible Taste. Infallible Results™; Infrared Inside™; Insure™; Let’s Grill Something Together™; Lev-Alert™;Longhorn™;

Magneto™; Precision Flame™; Quick2Burn™; QuickSet™; Ready When You Are™; Season, Set, And Savor™; Sizzle On The Grill™; Signature Series™; SureFire™; The Minute Grill™;Torchfork™; Universal Grill Parts™; You Bring the Party™ TEC™ is a trademark of Tec Infrared Grills.

Protected under one or more of the following U.S. Patents: 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,135,104; 6,279,566; 6,331,108; 6,484,900; 6,526,876; 6,595,197; 6,640,799; 6,640,803; 6,729,873; 6,739,473; 6,749,424; 6,792,935; 6,951,213; 7,047,590; 7,516,693; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910; D405,643; D406,005; D406,009 ; D413,043; D413,229; D414,982; D415,388; D416,164; D416,441; D417,587; D417,588; D422,516; D423,274; D423,876; D428,303; D430,772; D435,396; D436,004; D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D443,464; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D450,544; D451,759; D454,028; D454,031; D455,205; D455,206; D456,202; D456,222; D456,223; D457,789; D458,520; D458,760; D458,802; D459,088; D459,148 D459,149; D459,161; D459,163; D459,586; D459,943; D460,312; D460,313; D460,318; D461,359; D465,123; D465,693; D466,307; D466,439; D466,752; D473,414; D474,371; D477,498; D477,501; D477,504; D477,506; D477,746; D478,471; D478,472; D480,914; D491,410; D494,009; D494,413; D498,523; D500,359; D504,048; D530,098; D535,000; Canada:D97,504;D99,355; D102,037; D104,200;D108,377; 2,315,567; France:D010,231;D010,422;D010,590;D010,849; 1,089,646; South Korea: 384,565; United Kingdom: 2,099,402. Other Patents Pending. © 2009 W.C. Bradley Company TM REVISION 03

© 2008 Char-Broil,LLC • Columbus, GA 31902 • Printed in China • Assembly Instructions © 2009

10101550• 42804468 • 12-01-09

TABLE OF CONTENTS

Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Food Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

This instruction manual contains important information necessary for the proper assembly and safe use of the appliance.

Follow all warnings and instructions when using the appliance.

Do not use this appliance on or under any apartment or condominium balcony or deck.

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

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

WARNING

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

CAUTION

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

DANGER

1.Never operate this appliance unattended.

2.Never operate this appliance within 10ft (3m) of any structure, combustible material or other gas cylinder.

3.Never operate this appliance within 25 ft (7.5 m) of any flammable liquid.

4.If a fire should occur, keep away from the appliance and immediately call your fire department.

Failure to follow these instructions could result in fire, explosion or burn hazard, which could cause property damage, personal injury or death.

DANGER

If you smell gas:

1.Shut off gas to the appliance.

2.Extinguish any open flame.

3.Open lid.

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

Failure to follow these instructions could result in fire or explosion, which could cause property damage, personal injury or death.

WARNING

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

CAUTION

For residential use only. This appliance is not intended for commercial use.

Page 2

Installation Safety Precautions

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

The appliance 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, and Propane Storage and Handling, CSA B149.2, Canadian Electrical Code, CSA C22.1 or the Standard for Recreational Vehicles, ANSI

A 119.2/NFPA 1192, and CSA Z240 RV Series, Recreational Vehicle Code, as applicable.

This appliance is not for use in or on recreational vehicles and/or boats.

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

WARNING

CALIFORNIA PROPOSITION 65

1.Combustible by-productsproduced when using this product contains chemicals known to the State of California to cause cancer, birth defects, or 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.

Page 3

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.

Grease Tray

• Never use drippings directly from the grease tray to make gravy. Use the included foil tray liner to catch drippings, then reheat the drippings to kill bacteria. Replacement foil tray liners and other accessories can be found at www.charbroil.com.

How To Tell If Meat Is Cooked Thoroughly

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

We recommend food to be at least 40°F before cooking in your appliance.

Whole poultry should reach 165° F. Juices should run clear and flesh should not be pink.

Beef, veal and lamb steaks, roasts and pork chops can be cooked to 160° F.

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

Use a meat thermometer to ensure proper internal food temperatures.

USDA Recommended

Internal Cooking Temperatures

Ground Meat

 

Beef, Pork, Veal, Lamb......................................

160°F

Turkey, Chicken.................................................

165°F

Fresh Beef, Veal, Lamb

 

Medium Rare.......................................................

145°F

Medium................................................................

160°F

Well Done............................................................

170°F

Poultry

 

Chicken & Turkey, whole.....................................

165°F

Poultry Parts.......................................................

165°F

Duck & Goose....................................................

165°F

Fresh Pork

 

Medium..............................................................

160°F

Well Done..........................................................

170°F

Storing Your Appliance

Clean cooking basket.

Store in dry location.

When LP cylinder is connected to appliance, store outdoors in a well-ventilatedspace and out of reach of children.

If the regulator is disconnected from the LP cylinder, a hook is provided to hang the regulator from the handle as shown.

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

Store indoors ONLY if LP cylinder is turned off and is disconnected, removed from appliance and stored outdoors.

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

“For Best Results”

Place poultry into the appliance

with breast up as shown.

Page 4

Retainer Strap

USE AND CARE

DANGER

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

Never fill a cylinder beyond 80% full.

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

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

Keep LP tank at a minimum distance of 24” (inches) away from appliance at all times.

24”

LP Cylinder Removal, Transport and Storage

Turn OFF the 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 (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.

• A disconnected LP cylinder in LP Cylinder Valve

 

storage or being transported

 

must have a safety cap installed (as shown).

 

Do not store an LP cylinder in enclosed spaces

 

such as a carport, garage, porch, covered

Safety

patio or other building. Never leave an LP cylinder

inside a vehicle which may become overheated

Cap

 

by the sun.

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

LP Cylinder

The LP cylinder used with your appliance 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 the National Standard of Canada, CAN/CSA-339,Cylinders, Spheres and Tubes for Transportation of Dangerous Goods; and commission, as applicable. See LP cylinder collar for marking.

LP cylinder valve must have:

• Type 1 outlet compatible with

 

regulator or appliance.

 

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 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.

Page 5

LP Cylinder Exchange

Many retailers that sell this appliance 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 the appliance.

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

LP Cylinder Leak Test

For your safety

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

Do not smoke during leak test.

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

This appliance must be leak tested outdoors in a well-ventilatedarea, 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 paintbrush and a 50/50 mild soap and water solution. Brush soapy solution onto areas indicated by arrows in figure below.

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

WARNING

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. (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.

lo

ck

 

wi

ffC

 

se

O

 

 

OPD Hand Wheel

Type 1 outlet with thread on outside

Safety Relief Valve

Strap and Cap

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

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.

Page 6

Straight

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

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

NOTE:

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

Leak Testing Valves, 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 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.

DANGER

Do not insert any tool or foreign object into the valve

 

outlet or safety relief valve. You may damage the valve

 

and cause a leak. Leaking propane may result in

 

explosion, fire, severe personal injury, or death.

 

WARNING

This appliance is not intended to be installed in or on a

 

boat.

This appliance is not intended to be installed in or on an

 

RV.

Never attempt to attach this appliance to the self-

 

contained LP gas system of a camper trailer or motor

 

home.

• Do not use this appliance untilleak-tested.

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

 

department.

If you cannot stop a gas leak, immediately close LP

 

cylinder valve and call LP gas supplier or your fire

 

department!

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 at the number listed on front cover.

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

Page 7

WARNING

For Safe Use of Your appliance and to Avoid Serious Injury:

The use of alcohol, prescription or non-prescriptiondrugs may impair the consumer's ability to properly assemble or safely operate the appliance.

When cooking, the appliance must be on a level, stable noncombustible surface in an area clear of combustible material. An asphalt surface (blacktop) may not be acceptable for this purpose.

Do not leave appliance unattended. Keep children and pets away from the appliance at all times.

Do not place empty cooking vessel on the appliance while in operation. Use caution when placing anything in cooking vessel while the appliance is in operation.

Do not move the appliance when in use. Allow the cooking vessel to cool to 115°F (45°C) before moving or storing.

This appliance is not intended for and should never be used as a heater.

This appliance will be hot during and after use. Use insulated oven mitts or gloves and long-handledbarbecue utensils for protection from hot surfaces or splatter from cooking liquids.

Keep appliance area clear and free from materials that burn.

Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

Keep fuel supply hose away from any heated surfaces.

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

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.

3

.

ft

ft

3

.

 

24”

Page 8

• 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 any type of closed cover . A buildup ofnon-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.

Safety Tips

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

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

The grease tray must be inserted into appliance and emptied after each use.

If you notice grease or other hot material dripping from appliance 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.

Do not store objects or materials under the appliance enclosure that would block the flow of combustion air to the underside of either the control panel or the firebox bowl.

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

If you have an appliance problem see the "Troubleshooting Section".

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

Clean 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.

CAUTION

Putting out grease fires by closing the lid is not possible. This appliance is 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 appliance unattended while burning off food residue. Ifappliance has not been regularly cleaned, a grease fire can occur that may damage the product.

Ignitor Lighting

Do not lean over appliance while lighting.

Read all instructions before lighting.

1.Turn ON LP gas cylinder.

2.Open lid during lighting.

3.Press and turn the control knob to HIGH.

4.Turn ROTARY IGNITOR knob rapidly.

5.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-lightinginstructions.

WARNING

Turn control knob and LP cylinder OFF when not in use.

CAUTION

If ignition does NOT occur in 5 seconds, turn the control knob 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.

Match-Lighting

Do not lean over appliance while lighting.

1.Turn ON LP cylinder.

2.Swing match hole plate to expose match lighting hole. Place lit match into match lighting hole of appliance as pictured below. Make sure lit match is placed inside hole and near burner.

3.Push in and turn control knob to HIGH. Be sure burner lights and stays lit.

4.Once lit, swing match hole plate back to cover up match lighting hole. Caution: Plate maybe hot.

Control

Knob

Match

Match

Lighting

Hole

Hole

Plate

 

Swing Plate

 

to expose

 

Matchlighting

 

Hole

 

 

Match

View is from side of appliance

Burner Flame Check

Light burner. Looking through viewing hole on top of appliance, you should see the flame height as shown below. Turn control knob from HIGH toLOW. The Flame height should decrease and then go out. Always check flame prior to each use. If only low flame is seen refer to "Sudden drop or low flame" in the

Troubleshooting Section.

High Flame

Low Flame

Turning Appliance Off

Turn control knob to OFF position. Turn LP cylinder off by turninghand-wheelclockwise to a full stop.

Ignitor Check

Turn gas off at LP cylinder. Turn ignitor knob. "Click" should be heard each time at electrode. See "Troubleshooting" if no click or spark.

Valve Check

Important: Make sure gas is off at LP cylinder before checking valve. Knob locks in OFFposition. To check valve, first push in knob and release, knob should spring back. If knob does not spring back, replace valve assembly before using this appliance. Turn knob to LOWposition then turn back to OFFposition. Valve should turn smoothly.

Hose Check

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

Normal

Kinked

Hose

Hose

General Appliance Cleaning

Meat Thermometer: Do not immerse or soak in water. Wash with warm soapy water and wipe dry.

Do not mistake brown or black accumulation of grease and smoke for paint. Interiors 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 appliance lid and bottom. Rinse and allow to completely air dry.

Do not apply a caustic grill/oven cleaner to painted surfaces. A black surface improves the appliances performance.

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.

Painted surfaces: Wash with mild detergent ornon-abrasivecleaner and warm soapy water. Wipe dry with a soft nonabrasive cloth.

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.

Page 9

CAUTION

SPIDER ALERT!

SPIDER AND WEBS

INSIDE BURNER

Please note that the burner shown is for illustration purposes only. The burner in your product may be different from the one shown.

If you notice that your the appliance 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.

VALVE

SPIDER WEBS

CONTROL PANEL

INSIDE VENTURI

BURNER

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 the appliance’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 the appliance and even cause injury.

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

Cleaning the Burner Assembly

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

1.Turn gas OFF at control knob and LP cylinder and disengage regulator from cylinder.

2.Open top cover, remove cooking basket and cooking Chamber, shown A. This will expose the burner from inside, shownB.

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

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

5.Carefully lay the appliance on its back, with control panel facing up shown C.

6.Disconnect electrode wire underneath appliance, shown C.

7.Remove screws and disengage front legs from appliance.

8.Remove screws and disengage control panel assembly and Page 10heat shield from unit, shownD.

Cleaning the Burner Assembly (Continued)

9.Clean inner burner as recommended below, shown E. We suggest three ways to clean the burner tube. Use the one easiest for you.

(A)Bend a stiff wire (a light weight coat hanger works well) into a small hook. Run hook through 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 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.

10.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.

11.Carefully replace heat shield and control panel assembly .

12.Reattach electrode wire to ignitor.

VERY IMPORTANT: Burner tube must re-engageover valve opening. See illustration, shown F.

11. Reattach front legs. Carefully stand the unit upright.

13. Reposition inner liner, cooking basket.

A

B

Cooking

Burner

Basket

(exposed)

Cooking

Chamber

Carefully place

C

Control

D

unit on its back.

 

Panel

Heat Shield

 

Assembly

 

 

 

Burner

Electrode

 

 

Tube

 

 

 

Wire

 

 

 

Remove

 

 

 

Front Legs

Remove Screws

 

 

Tube cleaner

E

 

F

(see above

 

 

 

recommendations)

 

 

 

Burner Tube

Valve

Burner

Valve engaged inside burner

tube end correctly

(exposed) (Control panel and heat sheild hidden for clarity)

LIMITED WARRANTY

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

SCOPE OF COVERAGE

PERIOD OF COVERAGE

TYPE OF FAILURE COVERAGE

All Parts

90 days from date of purchase*

PERFORATION, MANUFACTURING,

 

 

AND MATERIAL DEFECTS ONLY

 

 

 

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

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

This limited warranty is applicable in the United States and Canada only, is only available to the original owner of the product and is not transferable. Manufacturer requires proof of your date of purchase. Therefore, you should retain your sales slip or invoice. Registering your product is not a substitute for proof of purchase and the manufacturer is not responsible for or required to retain proof of purchase records.

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

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

ITEMS MANUFACTURER WILL NOT PAY FOR:

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

2.Service calls to your home.

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

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

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

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

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

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

DISCLAIMER OF IMPLIED WARRANTIES and LIMITATION OF REMEDIES

Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. Manufacturer will not be responsible for any consequential or incidental damages arising from the breach of either this limited warranty or any applicable implied warranty, or for failure or damage resulting from acts of God, improper care and maintenance, grease fire, accident, alteration, replacement of parts by anyone other than Manufacturer, misuse, transportation, commercial use, abuse, hostile environments (inclement weather, acts of nature, animal tampering), improper installation or installation not in accordance with local codes or printed manufacturer instructions.

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

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

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

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

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

write to:

Consumer Relations

P. O. Box 1240

Columbus, GA 31902-1240

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

refused.

WS_1 Rev02

Page 11

PARTS DIAGRAM

 

 

I

U

 

 

 

K

K

 

 

 

 

 

 

 

J

 

 

J

CC

 

 

 

 

 

 

 

 

 

 

 

O

 

 

 

 

C

DD

 

B

H

X

 

 

A

 

 

 

 

Z

 

 

 

 

 

 

 

 

 

 

V

 

 

 

 

 

T

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D

 

L

 

 

F

 

 

M

 

 

W

 

 

 

E

 

N

 

 

 

 

 

 

K

 

 

 

 

 

 

 

 

 

 

 

 

Y

 

 

 

 

 

 

 

 

 

 

 

 

G

 

 

 

 

 

S

BB

 

 

 

 

 

 

 

 

 

R

 

 

P

 

 

 

 

 

 

 

 

 

 

AA

 

 

Q

 

 

 

 

 

 

 

 

 

 

 

 

 

Key

Qty

Description

Key

Qty

Description

Key

Qty

Description

A

1

Outer Body

M

1

Ignitor Knob

Y

1

Wind Shield

B

1

Inner Body

N

1

Control Knob

Z

2

Wire Grate, Half Rack

C

1

Body Top Ring

O

1

Top Lid

AA

4

Burner Support

D

1

Burner

P

4

Leg Assembly

BB

1

Top Handle

E

1

Heat Shield

Q

1

Grease Tray

CC

1

Hinge Assembly, Right

F

1

Ignition Kit

R

2

Grease Tray Rails

DD

1

Hinge Assembly, Left

G

1

Logo Plate

S

1

Hose, Valve, Regulator Assembly

...

1

Hardware Pack

H

1

Cooking Chamber

T

1

Heat Shield

...

1

Assembly Manual, English

I

1

Roaster Basket

U

1

Lift Hook

...

1

Assembly Manual, Spanish

J

2

Side Handles

V

1

Meat Thermometer

 

 

 

K

3

Handle Springs

W

1

Cooking Grate Assembly

 

 

 

L

1

Control Panel

X.

1

Smoker Box Assembly

 

 

 

NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from those on your particular model. However, the method of assembly remains the same.

Page 12

ASSEMBLY

Tools required for assembly:

Phillips Screwdriver (Not Supplied); Small Adjustable Wrench (Not Supplied)

1

Carefully turn the unit upside down.

Slide Heatshield into place over the exposed burner tube.

Align hole in Heat Shield with end of Burner Tube

Heat Shield in Position

 

While holding the Heat Shield in place, slide the Control Panel Assembly into place, taking care to ensure that

2

 

the valve engages the burner tube. shown Figure A

Install two #10x3/8" self-tapscrews through the right side of the control panel. Leave screws loose.

Make sure valve is inside burner tube. Align the heat shield as shown Figure B.

Secure control panel using the two remaining #10x3/8” self-tapscrews. Tighten all four screws.

Fig. A

Burner Valve

TubeEnd

Proper Valve to Burner Tube installation

(veiw from underneath control panel)

Screw hole

Fig. B

for leg - used

 

later.

 

Heat shield

Control

Panel

Carefully insert valve end into burner tube making sure valve is centered with burner tube, after aligned correctly, loosely secure with two self-tapscrews on RH side of control panel.

Hold Heat Shield in place while attaching Control Panel

Screw hole for leg - used later.

Ignitor Wire

NOTE:

Ensure that the valve engages the burner tube

Qty: 4 #10x3/8" Self-TapScrew

NOTE:

Install these screws first!

Page 13

3

Attach round end of ignitor wire to electrode.

 

The ignitor wire is factory installed to the ignitor. Pass the loose end of the wire through the

 

hole in the body, shown Figure A

 

Place Windshield inside the bottom of the body. NOTE: Fasteners are not required for the windshield. .

 

 

The windshield is held in place once the legs are attached.

 

 

 

 

 

 

 

Ignitor

 

 

Wire

Ignitor

Figure A

Windshield

Grease Tray Rail

Figure B

Page 14

4

Install legs by engaging leg tabs over bottom edge of the

appliance body.

 

Once the leg is in place, attach two #10-24x1"screws

 

through the leg and into the appliance body.

 

Repeat for the remaining legs.

 

When all four legs are securely installed, carefully turn the

 

unit upright.

 

Slide the grease tray into the rear of the unit.

Qty: 8

#10-24x1"Screw

Leg Tabs shown

 

in proper

Grease tray

position.

rails

#10-24x1"Screw

Grease Tray

5

Attach the side handle assemblies to the unit using two #10-24x1/2"screw per

 

handle.

 

 

Install the control knobs on to the valve stem and the ignitor stem.

Qty: 4

#10-24x1/2"Screw

Control

Knob

Ignitor

Knob

#10-24x1/2"Screw

Page 15

6

Attach the hinges to the lid inserting a#10-24x3/8"screw into

hinge, install a fiber washer onto screw, align lid onto screw,

 

install fiber washer from inside the lid, and finally secure with a

#10-24Keps nut. Repeat for opposite hinge. ShownA.

Qty: 8

Fiber Washer

Qty: 4

Qty: 8

#10-24Keps Nut

#10-24x3/8"Screw

A

#10-24Keps nut

Fiber

Washer

#10-24x3/8"Screw

LH Hinge

RH Hinge

B

Install lid by aligning the LH and RH hinges at the rear of the unit and securing with 4 #10-24x3/8"screws as shown B.

7

Attach the lid handle by inserting a#10-24x1"screw into handle, install a fiber washer onto screw, align handle onto lid screw

 

hole, install fiber washer from inside the lid, and finally secure with a #10-24Keps nut.

 

 

 

Repeat for opposite side.

 

 

 

Slide the Cooking Chamber and Cooking Basket into the unit.

 

 

 

 

Qty: 4

Qty: 2

Qty: 2

 

 

Fiber Washer

#10-24Keps Nut

#10-24x1"Screw

#10-24x1"Screw

Fiber Washer

#10-24Keps nut

Page 16

Accessory Use and Storage

NOTE: Before cooking on your appliance for the first time, refer to the separate Cooking Guide on how to prepare the appliance for

cooking. It is recommended that you season your appliance prior to cooking.

Once seasoning is complete, the appliance is now ready for use. The cooking chamber will continue to darken with use. This will inhibit rusting along with improving the performance of the infrared cooking system.

The bottom of the Cooking Grate has a locating ring. Be sure that the locating ring faces down and is centered in the cooking Chamber when using theCooking Grate. Otherwise, theCooking Grate could slip off the top of the appliance.

Never use the Cooking Grate upside down!

Locating

Note:

Cooking Grate

Ring

shown

 

transparent

 

for clarity

Locating

Never use the

Ring on bottom

of Cooking Grate

Cooking Grate

 

upside down!

Cooking Grate shown in proper position.

When using the Cooking Basket, insert it into theCooking Chamber as

shown.

Cooking

Basket

Assembling your Half Racks into the cooking basket is very easy.

Just insert the Half Rack through the side of the cooking basket at the desired level.

Allow the Half Rack legs to rest securely on the cooking basket wire. Make sure the legs are OUTSIDE of the cooking basket. This prevents theHalf Racks from slipping.

All four Legs outside of cooking basket.

Two Half Racks are included with your Smoker, Roaster, & Grill. Please visit us atwww.charbroil.com and click on theBuy Online link to purchase additionalHalf Rack sets.

Page 17

Accessory Use and Storage

Smoker Box

The Smoker Box has a clip that secures it into one of the four vent holes on the top ring of the appliance. Insert the clip as shown. When smoking, you will use the smoker box with the cooking basket.

Insert clip into vent hole.

Smoker Box

shown in place.

Accessory storage

Accessory items such as the cooking grate, smoker box and half racks can be stored on board the Smoker, Roaster, & Grill as shown.

Smoker box in place along with cooking basket

All accessories properly stored.

Hanging hooks

Hole

Slot

Cooking Grate Storage

Smoker Box Storage

Half Rack Storage

Page 18

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

Emergencies

Possible Cause

Prevention/Solution

 

 

 

Gas leaking from

• Damaged hose.

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

cracked/cut/burned

 

hose is cut or cracked, replace valve/hose/regulator. See LP

hose.

 

Cylinder Leak Test and Connecting Regulator to the LP Cylinder.

Gas leaking from LP

• Mechanical failure due to rusting or

• Replace LP cylinder.

cylinder.

mishandling.

 

Gas leaking from LP

• Failure of cylinder valve from

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

cylinder valve.

mishandling or mechanical failure.

 

Gas leaking between

• Improper installation, connection not

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

LP cylinder and

tight, failure of rubber seal.

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

regulator connection.

 

and Connecting Regulator to the LP Cylinder.

Fire coming through

• Fire in burner section of burner due to

• Turn off control knob and LP cylinder valve. Allow flames to die

control panel.

blockage.

down. After fire is out and fryer 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 knob and LP cylinder valve. Allow flames to die

continuous excessive

 

down. After cooling, clean food particles and excess grease from

flames above cooking

 

inside appliance body, grease tray, and other surfaces.

surface.

 

 

 

 

 

Troubleshooting

Problem

Possible Cause

GAS ISSUES:

Burner will not light • Burner not engaged with control valve. using ignitor.

Obstruction in burner.

No gas flow.

Vapor lock at coupling nut to LP cylinder.

Coupling nut and LP cylinder valve not fully connected.

ELECTRICAL ISSUES:

Electrode cracked or broken; “sparks at crack.”

Electrode tip not in proper position

Wire and/or electrode covered with cooking residue.

Wire is loose or disconnected.

Wire is shorting (sparking) between ignitor and electrode.

Prevention/Solution

Make sure valve is positioned inside of burner .

Ensure burner is 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 knob 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.

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

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

Reconnect wire or replace electrode/wire assembly.

Replace ignitor wire/electrode assembly.

Page 19

Troubleshooting (continued)

Problem

Possible Cause

Prevention/Solution

 

 

 

Burner will not light

• Rotary knob rotates without clicking.

• Replace knob.

using ignitor.

• Sparking between ignitor and electrode.

• Inspect wire insulation and proper connection. Replace wire if

 

 

 

insulation is broken.

 

 

 

 

• See “GAS ISSUES:” on previous page.

 

Burner will not match

• Match will not reach.

• Use long-stemmatch (fireplace match).

light.

• 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 on regulator tripped.

• Turn off control 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-test.Turn on LP cylinder

 

 

valve, wait 30 seconds and then light appliance.

 

• Vapor lock at coupling nut/LP cylinder

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

 

connection.

cylinder. Reconnect and retry.

 

 

 

Flames blow out.

• Low on LP gas.

• Refill LP cylinder.

 

• Excess flow valve tripped.

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

 

 

 

Flare-up.

• Grease buildup.

• Clean burner and inside of fryer body.

 

• 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 knob to OFF. Turn gas off at LP cylinder. Let fire burn out. After

 

burner system.

fryer cools, remove and clean all parts.

 

 

 

Flashback...

• Burner is blocked.

• Turn knob to OFF. Clean burner. See burner cleaning section of Use

(fire in burner ).

 

and Care.

 

 

 

Unable to fill LP

• Some dealers have older fill nozzles

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

cylinder.

with worn threads.

a second LP dealer.

 

 

 

Cooking slower than

• Vapor Lock

• Turn off control knob and disconnect coupling nut from LP cylinder.

Reconnect and retry.

expected

• Valve not properly aligned to burner

• Loosen control panel and valve. Be sure valve is centered top to

 

 

• High wind conditions

bottom and left to right in burner . Tighten all components once

 

proper alignment is achieved.

 

 

• Relocate the appliance to a less windy area. Use Top Cover during

 

 

cooking.

 

 

 

Page 20

Notes

Page 21

Notes

Page 22

REGTEMP REV00

Page 24