Charbroil 10401609 Owner's Manual

Owner’s Manual

®

Assembly, Operation, Use and Care

MODEL 10401609

THIS GRILL IS FOR OUTDOOR USE ONLY.

DANGER

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

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

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

WARNING

1. Do not store or use gasoline or other
flammable liquids or vapors in the vicinity of
this or any other appliance.

2. An LP cylinder not connected for use shall not
be stored in the vicinity of this or any other
appliance.

INSTALLER/ASSEMBLER: Leave these instructions with

consumer.
CONSUMER: Keep this manual for future reference.

WARNING

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

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

Follow all warnings and instructions when using the
appliance.

Keep this manual for future reference
Combustion by-products produced when using this product

contain chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

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 duringassembly, please call .1-800-232-3398

To insure your satisfaction and for follow-up service r e g i,ster your grill online at www.grillregistration.com

10401609 • 42804523 • 09-08-09

Table of Contents

CAUTION

For Your Safety

Grill ServiceCenter. .. . . ... . . .. . . . .. . . .. . . . .. . . ... . . .. 2

Product RecordInformation . . .. . . ... . . .. . . . .. . . .. . . . .. . 2

Installation SafetyPrecautions. . ... . . .. . . . .. . . .. . . . .. . . .2

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

Table of Contents. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . ... . . .. 3

Use andCare . .. . . . .. . . ... . . .. . . ... . . .. . . . .. . . .. . . 4-7

Parts List. . . . .. . . ... . . .. . . ... . . .. . . . .. . . .. . . . .. . . .. . 8

Parts Diagram. . . . .. . . ... . . .. . . . .. . . .. . . . .. . . .. . . . .. . 9

Assembly. . . . .. . . .. . . . .. . . .. . . . .. . . ... . . .. . . ... . 10-14

Storing and Transporting

Troubleshooting. . .. . . .. . . . .. . . .. . . . .. . . ... . . .. . . .16-17

Warranty

Registration Card . . . .. . . ... . . .. . . . .. . . .. . . . .. . . .. . . .

Important: Fill out Warranty information below

. .. . . . .. . . ... . . .. . . ... . . .. . . . .. . . .. . . . 2

. .. . . . .. . . ... . . .. . . ... . . .. . . . .. . . .. . . . .

. .. . . . .. . . ... . . .. . . ... . . .. . . . .. . . ..

15

18
19

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

CAUTION

• Keep the fuel supply hose away from any heated
surfaces.

• For residential use only. Not intended for commercial use.

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

Installation Safety Precautions

• Use grill, as purchased, only with LP (propane) gas and the

regulator/valve assembly supplied.

• 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. Storage and handling of
liquefied petroleum gasses must conform to LP Gas Code
ANSI / NFPA 58. Grill is not for use in or on recreational
vehicles and/or boats.

Warranty Information

Model Number

Serial Number

See rating label on grill for serial number.

Date Purchased

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

• 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.

• Keep the fuel supply hose away from any heated
surfaces.

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

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.

2

Use and Care

WARNING

For Safe Use of Your Grill and to Avoid Serious

Injury:

•

Do notletchildren operate or playnear grill.
Keep grillareaclear and free frommaterials that burn (i.e.

•

gasoline, propane,orany other flammable liquidor gas).

•

Do notblockholes in bottom orback of grill.

•

Check burnerflamesregularly.

• Never useregulator from this grill withany other LP
appliance.

• When cooking,the appliance must be ona level surface in
an areaclearof combustible material.

Use grillonlyin well-ventilated space. NEVERuse in

•

enclosed spacesuchas carport, garage, porch,covered
patio, orunderan overhead structure ofany kind.

Do notusecharcoal or ceramic briquetsin a gas grill.

•

Unless briquets are supplied with your grill.)

(

• This applianceis not intended for andshould never be used
as aheater.

• Use grill at least 3 ft. from any wall or surface.

10 ft.clearanceto objects that cancatch fire or sourcesof
ignition suchaspilot lights on waterheaters, live electrical
appliances, etc..

A

3 ft. (1m) minimum

10 ft. recommended

Maintain

LP (Liquefied Petroleum Gas)

Is nontoxic,odorlessand colorless when produced.

• For Your
Safety

, LPgas has been givenan odor (similar to rotten

cabbage) sothatit can be smelled.

• LP gas is highly flammable and may ignite unexpectedly
when mixed with air.

Propane Cylinder Use (1 lb. Disposable)

Use onlycylindermarked “Propane Fuel”.

•

•

Cylinder mustbeconstructed and marked inaccordance with
the specificationsforLP-gas cylinders of theU.S. Department
ofTransportation (DOT) or theNational Standard of Canada,
CAN/CSA-B339, Cylinders,Spheresand Tubesfor the
Transportationof Dangerous Goods.

•

Size shouldbe4” diameter, 8”height, or 3” diameter, 10”
height.

•

Save cylindercapand reinstall when notin use.

•

Cylinder supplysystemmust be arranged forvapor
withdrawal. Gascylindermust be upright inuse.

Leak Testing (1 lb. Disposable)

• During leaktest, keep grill awayfromopen flames or sparks
and donotsmoke. Grill must beleak tested outdoors inawell
ventilated area.

Leak testmustbe repeated each timegas cylinder is replaced

•

or afterstorage.

Materials neededincludeclean paint brush and50/50 soap and
water solution.Usemild soap and water.

household cleaning agents.

result.

Be sure on regulatorisin "OFF" position.

1. control knob

Brush soapysolutiononto between gascylinder

2. connection

and regulatorat .

If growingbubblesappear,there is aleak. Retighten
connection andrepeatsteps 1 and 2.

(A)

IMPORTANT!

Do not use

Damage tocomponentscan

• Apartment Dwellers:

Check withmanagementto learn the requirementsand fire
codes forusingan LP gasgrill in your apartment complex.
If allowed,useoutside on the groundfloor with a three(3)
foot clearancefromwalls or rails. Donot use on orunder
balconies.

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

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

.

If youcannot stop a leak,removegas
cylinder fromregulatorand check for

A

damaged threads,dirtand debris on
regulator andgascylinder.Also check to
see ifanythingis obstructing flow ofgas at
regulator andgascylinder openings.
Remove anyobstructionthat may be
found andrepeatleak test.

damaged on either regulator or gas
cylinder, replace.

giving theserial,model number and name
of itemsneededto the Grill ServiceCenter
at .

1-800-232-3398

Order newpartsby

If threads are

3

DANGER

CAUTION

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

• Never fill a cylinder beyond 80% full.

• An overfilled or improperly stored cyclinder 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.

Safety Tips

The useofalcohol, prescription or nonprescriptiondrugs
may impairtheconsumer’s abilityto properly assemble or
safely operatetheappliance.

When grillisnot in use, disconnect1 lb. cylinder.
Never movegrillwhile in operation orstill hot. Allow the

appliance tocoolbefore moving or storing.
Use onlytoolssupplied or plastic tools.
Maximum loadforside shelves is 10lbs.
The regulatormaymake a humming orwhistling noise

during operation.This will not affectsafety or useofgrill.
If youhavea grill problem seethe TroubleshootingSection.
Light burners.Checkto make sure theyare lit, close thelid

and warmupgrill on high for 2 0 minutes. Curing of paint
and partswillproduce an odor onlyon first lighting.

Grill isnotto be used asa heater.

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.

Match Lighting

1. Attach match to match lighting stick, light match.

2. Insert lit match through grate and next to burner. Turn gas on
for appropriate burner. Repeat for other burner.

Match
lighting
stick

Ignitor Lighting

Do not lean over grill while lighting.

1. Open lid during lighting.

connected toregulator.

2.

TurnLEFT knob to .

3.

Turnrotary ignitor knob (up to 5 times) tolight. Be sure
burner lightsandstays lit.

4.

If ignitiondoesNOToccur in 5seconds, turn the burner
controls OFF, wait 5 minutes andrepeat the lighting
procedure.

5.

Toignite RIGHT burner, turn right knobto and repeat
steps 3-4.

6.

If IGNITOR does not work,follow match lighting instructions.

Make sureLPcylinder is properly

WARNING

Turn controls OFF and disconnect cylinder when not
in use.

Before Your First Cookout.

Before Your First Cookout.

Leak test your grill L .ightburners, check to makesurethey are

lit, closethelid and warm upgrill on HIGH for10minutes. Curing
of paintandparts will produce anodor only on firstlighting.

Turning Grill Off

• Turnknobs to OFFposition.Make sure knobs popup. If it
does not,discontinueuse and order newpart.

• Disconnect 1lb.Cylinder.

Hose Check

• Before eachuse,check to see if

hoses arecut,worn or kinked.
Replace damagedhosesbefore
using grill.Useonly
valve/hose/regulator specifiedby
manufacturer.

Normal
Hose

Kinked
Hose

4

CAUTION

CAUTION

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

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

Burner Flame Check

Light burner. Make sureburnerstays
lit whilerotatingthe control knob
from HIGHtoLOW. Alwayscheck
flame priortoeach use.

Cleaning The Burner Assembly

Turn gas off at control knobs and LP cylinder.

1.

2. Remove cookinggrids and vaporizer tents.

3. Remove palnuts on burners. Unscrew electrodeand move
to thesideto remove burner.

out.

4. Under grillremove grease tray. Clean with soapand water.

5. Wipe ceramicelectrode with rubbing alcohol andcloth.

6. Clean burnersexterior with soap and water. Lay burnerson
flat surface,insertgarden hose (preferably withnozzle), into
burner tubesforcingwater through tubes. Makesure water
comes outofevery porthole. Open cloggedportholes with a
thin wire. and examineporthole.
Due tonormalwear and corrosion someportholes may
become enlarged,ifso replace burner. If any horizontal
cracks appearfromporthole to porthole orlarge holes (other
than portholes)arefound replace burner.

7. If grillis to be stored, coatburners lightly with cookingoil.
Wrapin protective cover to keepinsects out. If notstoring
use followingsteps.

VERY IMPORTANT: Burner tubes must engage valve
openings as shown (A).

8. Reattach burnersand electrodes.

9. Reposition cookinggrids and vaporizer tents. Placeclean
grease trayintogrill bottom.

10. Before cooking againon grill,
perform a and

“Burner Flame Check”

Shake out excess water

“Leak Test”

Valve

NOTE: Do not pull electrode

A

.

Burner
Tube

Burner tubescorrectly
engaged invalves

NATURAL HAZARD • SPIDERS

FACT:

Sometimes spiders and other small insects climb
into the burner tubes attached to the burners.The
spiders spin webs, build nests and lay eggs.The

webs or nests can be very small, butthey
are very strong and can block the flow
of gas. Clean burners prior to use after
storing, at the beginning of grilling season
or after a period of one month notbeingused.

Spider guards are on the air intakesinaneffortto

reduce this problem, but it will not eliminateit! An
obstruction can result in a "flashback" (a fireinthe
burner tubes).Thegrillmaystilllight,buttheobstruction
does not allow full gas flow to theburners.

IF YOU EXPERIENCE THE FOLLOWING:

Smell gas.

1.

Burner(s) will not light.

2.

Asmall yellow flame from burner (should be blue).

3.

Fire coming from around or behind control knob.

4.
STOP!
Immediately turn off gas at LP cylinder!
SOLUTION:
Wait for grill to cool.

Follow the “ ” instructions.
Clean burners often. Use a 12” pipe cleanertocleanout
the burner tubes.Youmay also force a stream of water
from a hose nozzle through burner tubes tocleanthem.

General Grill Cleaning

• Do notmistakebrown or black accumulationof grease and
smoke forpaint. Interiors of gasgrills are not paintedatthe
factory (andshouldnever be painted).Apply a strongsolution
of detergentandwater or use agrill cleaner with scrubbrush
on insidesofgrill lid and bottom.Rinse and allow to
completely airdry.

to painted surfaces.
Side Shelves:

• Washwith warm soapywaterand wipe dry.

Do notusecitrisol, abrasive cleaners, degreasersor a
concentrated grillcleaneron plastic side shelves.Damage to
and failureofshelves can result.

• Non-Stick Cooking Surface:

While stillwarm,pour a cup ofwater over cooking surfaceto
loosen greaseandfood particles and tospeed cool-down.
Wipe cookingsurfacewith a paper towelor sponge. Once
completely cool,cookingsurface can be removedand washed
with warmsoapywater or placed indishwasher.

.

Cleaning the Burner Assembly

Do not apply a caustic grill/oven cleaner

Turngrill offbefore cleaning.

5

Storing Your Grill

• Clean cookingsurfaceand grease container.

• When LPcylinder is connected togrill,store outdoors in well­ventilated spaceandout of reach ofchildren.

• Cover grillifstored outdoors.

• Store grillindoorsONLYif LP cylinderis turned offand
disconnected, removedfromgrill and stored outdoorsin well­ventilated spaceandout of reach ofchildren.

• Leak testthegrill after removing fromstorage and follow
Cleaning BurnerAssembly instructions beforestarting grill.

• Keep grillareaclear and free frommaterials that burner (i.e.
gasoline, propaneorother flammable liquid orgas).

• Do notblockholes in bottom orback of grill.

Non-Stick Cooking Surface Use and Care.

• Use onlyplastic tools.

• Do notcutfood on surface.

• Do notputpots or pans onsurface.

• Do notleavelid down for morethan 10 minutes withoutfood
on thegrill.Non-stick surface may bedamaged.

CAUTION

How To Tell If Meat Is Grilled Thoroughly

Meat andpoultrycooked on a grilloften browns very fastonthe

•

outside. Useameat thermometer to besure food has reached
a safeinternaltemperature, and cut intofood to check for
visual signsofdoneness.

•

Whole poultryshouldreach 180° F; breasts,170° F.Juices
should runclearand flesh should notbe pink.

•

Hamburgers madeofany ground meat orpoultry should reach
160° F, and be brown inthe middle with nopink juices. Beef,
veal andlambsteaks, roasts and chopscan be cooked to145°
F.All cutsof pork should reach 160°F.

•

NEVER partiallygrillmeat or poultry andfinish cooking later.
Cook foodcompletelyto destroy harmful bacteria.

•

When reheatingtakeoutfoods or fully cookedmeats like hot
dogs, grillto165° F,or until steaming hot.

When cooking on non-stick griddle, keep burner
set on low and keep lid open.

Food Safety

Food safetyisa very important partof enjoying the outdoor
cooking experience.To keepfoodsafe from harmful bacteria,
follow thesefourbasic steps:

Clean:

Separate:

Cook:

Chill:

For more information call: USDA Meat and Poultry Hotline at
1-800-535-4555 In Washington, DC [phone], 10:00 am-

4:00 pm EST

Washhands, utensils, andsurfaces with hot soapy water

before andafterhandling raw meat andpoultry.

.

Separate rawmeatsand poultry from ready-to-eat
foods toavoidcross contamination. Use aclean platter and
utensils whenremovingcooked foods.

Cook meatandpoultry thoroughly to killbacteria. Use a

thermometer toensureproper internal food temperatures.

Refrigerate preparedfoodsand leftovers promptly.

6