Char-Broil 640-174667113, 415.16121801 Product Manual

PRODUCT GUIDE

Kenmore Mode| No, 415.t6121801

Kmart item No, 640-174667113

IMPORTANT: Fill out the product record information below.

Serial Number

Seeratinglabelongrillfor serialnumber.

Date Purchased

Forsupportandtoregisteryour

grill,pleasevisit usat
www.charbroil.com

Ifyouhavequestionsorneed

assistanceduringassembly,
pleasecall1-800-241-7548.

Estimated assembly time: 35-40 minutes

The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Char-Broil®; America's Legendary Barbeque Company®;
American Gourmet®; Banders®; BrushHawg®; CB940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; DiamondFlame®; Everybody Grills®; Everybody Outside®;

FastStart®; Fireball®; Firenzy®; FlavorMaster®; Grill2Go®; Grill2Go® Express®; Grill Lovers®; H20 Smoker@; Keepers of the Flame®; New Braunfels Smoker
Company@; Oklahoma Joe's®; Patio Bistro@; Patio Caddie®; Patio Kitchen®; Precision Flame®; Quantum@; Santa Fe@; Sear and Grill@; Sierra@; Signature
Series@; The Big Easy@; The Minute Grill@;Trentino@; Wild West Tradition@; and the following marks:

The following are trademarks of W.C. Bradley Co.: Commercial Series ; Designer Series ; Grill2Go@ Advantage ; Longhorn ; Double Chef ; QuickSet ;

Ready When YouAre ; Hog and Yard Bird ; You Bring the Party ; SureFire ;Universal Grill Parts

TM

TEC is a trademark of Tec Infrared Grills.

Protected under oneor moreofthe following U.S.Patents:4,989,579; 5,421,319; 5,458,309;5,579,755; 5,996,573;6,114,666; 6,135,104;6,209,533; 6,279,566;6,331,108; 6,484,900; 6,526,876;6,595,197;6,640,799; 6,640,803; 6,729,873;6,739,473; 6,749,424;
6,863,t00; 6,935,327; 6,951,213;6792,935;7,047,590;D364,535;D372,637;D373,70t ;D377,735;D383,035;D397,9t0; D405,643;I}406,005; D4Od,OO9;I}413,043; D4t3,229; I}414,982; D4t5,388; I}4t6,164; D4t6,441; I}417,587;D417,588;D422,516;D423,876;

D428,303;D430,772;D435,396;D436,004;D438,059;D438,060;D438,427;D439,110; D442,505; D443,179;D443,354; D443,464; D447,384; D447,385; D447,909;D448,610;D448,614;D448,6t5; D448,616;D448,975; D449,492; D450,544; D451,759;D454,028;
D454,03t; Ii)455,205;D455,206;D456,202;D456,222;D456,223;I}457,789; D458,520; D458,760;D458,802; D459,088;I}459,148 D459,149;D459,16t; I}459,163; D459,586;D459,943;D460,312;D460,313;1}460,318;D461,359;D465,123;D465,693;D466,307;

D466,439;D466,752;D473,4t4; Ii)474,371;D477,498;D477,50t; D477,504; D477,506;I}477,746; D478,471; D478,472; D480,914; D49t,4t0; I)494,009; D494,4t3; D498,523;D500,359;D504,048;D530,098;D535,000;Canada:87,743;87,744; 97,504; 99,355;
102,037; 104,2OO;2,315,567;2,336,036;France: O10231;0t O,422;0t 0,590; O10,849;1,089,646;Germany:1,089,646;South Korea:384,565;China:99,127,066.5;UnitedKingdom:2,099,402;1,089,646.Other Patents Pending.

© 2008W.C. BradleyCompany

© 2008Char-Broil,LLC Columbus,GA 31902 Printedin China Assemblyinstructions©2008 Model 463612509 • 463612709 10/29/08.80018033

TM TM TM TM TM

TM TM TM TM TM TM

TM REVISION O0

For Your Safety .................................... 2-3

Use and Care .................................... 4-10

Grilling Guide .................................... 11-14

Limited Warranty.................................... 15

Parts List.......................................... 16

Parts Diagram...................................... 17

Assembly ....................................... 18-28

Troubleshooting.................................. 29-30

Registration Card ................................... 31

Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all ofthe messages found throughout

the manual.

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.

WARNING: Indicatesan potentiallyhazardous situation
which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION: Indicatesa potentiallyhazardoussituationor
unsafe practicewhich, if not avoided, may result in minor

or moderate injury.

DANGER: Indicatesan imminentlyhazardous situation
which, if not avoided,will resultin death orserious injury.

CAUTION

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

CAUTION:

Readand follow all safety statements,assembly
instructions,and use and care directions beforeattempting

to assemble and cook.

INSTALLER/ASSEMBLER:

Leavethis manualwith consumer.

CONSUMER:

Keepthis manualfor future reference.

WARNING:

Failureto follow all manufacturer's instructionscouldresult

in serious personal injuryand/or property damage.

CAUTION:

Some parts may containsharpedges- especiallyas noted
in the manual!Wear protectiveglovesif necessary.

CALiFORNiAPROPOSiTiON65

1.Combustionby-productsproducedwhenusing
thisproductcontainchemicals 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, CSAB149.1, or Propane Storage and
Handling Code, B149.2, or the Standard for Recreational

Vehicles,ANSI A 119.2/NFPA1192,and CSAZ240 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 70or Canadian
Electrical Code, CSA C22.1. Keep any electrical cords and/or

fuel supply hoses away from any hotsurfaces.

• This grill issafety certified for use in the United States and/or
Canada only. Donot modifyfor use in any other location.

Modification wilt result ina safety hazard.

CAUTIO.

exceed weight limit of the

Using pots larger than 6 quarts in capacity could _,

resulting in failure s

of grill cart _'_

components.

J

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. Useonly

authorized replacement parts supplied by
manufacturer.

• NEVERstore a spare LP cylinder under or near the
appliance or in an enclosed area.

• Never fill a cylinder beyond 80% full.

• ifthe informationin two points above is not

followed exactly, afire causing death or serious

injury may occur.

LP Cylinder

*The LP cylinder used with your grill must meet the

following requirements:

*Use LP cylinders only with these required measurements: 12"

(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.

,LP cylinders must be constructed and marked in accordance

with specifications for LP cylinders of the U.S. Department of
Transportation (DOT) or for Canada, CAN/CSA-B339,

cylinders, spheres and tubes for transportation of dangerous
goods. Transport Canada (TC). See LP cylinder collar for

marking.

*LPcylinder valve must have:

,Type 1 outlet compatible with

regulatoror grill.

,Safety relief valve.
,UL listed Overfill Protection OPDHandWheel

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.

• An over filled or improperlystored cylinder is a
hazard due to possible gas release from the safety

relief valve. This could cause an intensefire with
risk of property damage, serious injury or death.

• ifyou see, smell or hear gas escaping, immediately
get away from the LP cylindedappliance and call

your fire department.

LP Cylinder Removal, Transport and Storage

•Turn OFF all control knobs and LP cylinder valve. Turn coupling

nutcounterclockwise by hand only - do not use tools to

disconnect. Loosen cylinder screw beneathbottom shelf, then
lift LP cylinder up and out of cart. Install safety cap onto LP

cylinder valve. Always use capand strap supplied with valve.

Failure to use safety cap as directed may result in serious
personal injuryand/or property damage.

•Adisconnected LP cylinder in LPCylinder
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 LPcylinder Safety
inside a vehicle which may become overheated Cap

by the sun. RetainerStrap

•Do notstore an LP cylinder in anarea where children play.

LP cylinder in upright position for vapor withdrawal

LP (Liquefied Petroleum Gas)
*LPgas is nontoxic, odorless and colorless when produced. For

Your Safety, LPgas has been given an odor (similar to rotten
cabbage) so that it can be smelled.

*LPgas is highly flammable and may ignite unexpectedly when

mixedwith air.

LP Cylinder Filling
*Useonly licensed and experienced dealers.
*LPdealer must purge new cylinder before filling.
*Dealer should NEVER fill LP cylinder more than 80% of LP

cylinder volume. Volumeof propanein cylinder wilt vary by
temperature.

*Afrosty regulator indicates gas overfill. Immediately close LP

cylinder valve and call local LP gas dealer for assistance.

,Do not release liquid propane (LP) gas into the atmosphere.

This is a hazardous practice.

,To remove gas from LP cylinder,contact an LP dealer or call a

local fire department for assistance. Check the telephone
directory under "Gas Companies" for nearest certified LP

dealers.

LP Cylinder Exchange

Connecting Regulator to the LP Cylinder

•Many retailers that sell grills offer you the option of replacing
your empty LP cylinder through an exchangeservice. Use only

those reputable exchange companiesthat 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 isexchanged
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-ventilated area,

away from ignitionsources such as gas fired or electrical
appliances. Duringleak test, keep grill away from open flames

or sparks.

•Usea clean paintbrush and a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated byarrows

in figure below.

A Do not use household cleaning agents. Damage to gas

train components can result.

1.LP cylinder mustbe 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-wheel clockwise to a
full stop.

4.Remove the protective cap from LPcylinder valve. Always use
cap and strap supplied with valve.

OPD Hand Wheel

//- Type1outlet with

threadon outside

Safety Relief Valve

/

Strapand Cap

Do not use a POL transport plug
(plastic part with external threads)!

It will defeat the safety feature of
the valve.

If"growing" bubbles appear do not useor move theLP
cylinder.Contact an LPgas supplier or your fire
department!

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 to cross-thread the connection.

Nipplehas to be centered

intothe 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.

Holdcoupling nut and regulator
asshownfor properconnection

to LP cylindervalve.

6.Turn the coupling nut clockwiseand tighten to a full stop. The
regulatorwill 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 completethe
connection, do not use this regulator!

Do not insertany tool or foreignobject intothe valve

outlet or safety relief valve. You may damage the valve

and cause a leak. Leaking propane may result in
explosion,fire, severepersonal injury,or death.

4.Brush soapy solution onto areas circled below.

Outdoorgas appliance is not intended to be installed
in or on a boat.

Outdoorgas appliance is not intended to be installed
in or on an RV.

. Never attempt to attach this grill to the self-contained

LPgas system of a campertrailer or motorhome.
. Do not usegrill until leak-tested.
. If a leak is detected at any time, STOP and call the fire

department.
. If you cannotstop a gas leak,immediately close

LPcylindervalve and call LPgas supplieror yourfire

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.

6.Always close LPcylinder valve after performing leak test by

turning hand wheel clockwise.

zL zL

For Safe Use Of Your Grill And To Avoid Serious

Injury:

*Do not let children operate or play near grill.

•Keepgrill area clear and free from materialsthat burn.

•Do not block holes in bottom or back of grill.

•Check burner flames regularly.

•Usegrill only inwell-ventilated space. NEVERuse in
enclosed space such as carport, garage, porch, covered

patio, or under anoverhead 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 3ft. from any wall or surface. Maintain

10 ft. clearance to objects that can catch fire or sources of
ignitionsuch as pilot lights on water heaters, live electrical

appliances, etc.

Safety Tips
,& Beforeopening LP cylinder valve, check the coupling nut for

tightness.

,& When grill is not in use, turn off all control knobs and LP

cylinder valve.

,& If the outdoor cooking gas appliance is not in use, the gas

must be turned off at the supply cylinder. Storage of an

outdoor cooking gas appliance indoorsis permissible only if
the cylinder is disconnected and removed from the appliance.

,& Never move grill while in operation or still hot.
,& Use long-handled barbecue utensils and oven mitts to avoid

burnsand splatters.

,& Maximum load for side shelves is 10 Ibs.
,& The grease cup must be inserted into grease clip and

emptied after each use. Do not remove grease cup until grill

has completely cooled.

,& 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 recommendedto clean cooking surfaces

while grill is hot.

,& If you notice grease or other hot material dripping from grill

onto valve, hose or regulator,turn off gas supply at once.

Determinethe cause, correct it, then clean and inspect valve,
hoseand regulator before continuing. Perform a leak test.

,& The regulator may make a humming or whistling noiseduring

operation. This will not affect safetyor use of grill.

,& Onlyuse the pressure regulator and hose assembly supplied

with this grill. Replacementpressure regulator and hose
assemblies must be specified or supplied by Char-Broil, LLC.

,& If you have a grill problem see the "Troubleshooting Section".
,& If the regulator frosts, turn off grill and LP cylinder valve

immediately.This indicatesa problemwith the cylinder and it

should notbe used on any product. Return to supplier!

*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. Donot use on or under

balconies.

•NEVERattempt to light burner with lid closed. A buildup
of non-ignited gas inside a closed grill is hazardous.

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

•Always close LP tank valve and remove coupling nut

before moving LP tank from specified operation
position.

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.

ignitor Lighting

A Do not lean over grill while lighting.

1. TurnOFF gas burner control valves.

2. TurnON gas source or tank.

3. Open lid during lighting.

4. Toignite, turn left knob to,_ HIGH.

5. Push IGNITOR button rapidly.

6.If ignitiondoes NOT occur in5 seconds, turn the burner
controls OFF, wait 5 minutes and repeat the lighting
procedure.

7. To ignite right burner,turn knob to _.

If ignitor does notwork, follow matchlighting instructions.
After Lighting: Turn knobs to HI position for warm-up.

CAUTioN

If burner does not light, turn knobs to OFF,wait 5

minutes, and try again. Always close valve during the 5
minute waiting period, if the burner does not ignite with

the valve open, gas will continue to flow out of the burner
and could accidentally ignite with risk of injury.

Match-Lighting

Sideburner Ignitor Lighting

1. Turn OFF gas burner control valves.

2. Turn ONgas source or tank.

3. Turn sideburner knobto HI. and push IGNITOR button rapidly.

4. Ifsideburner does NOT light, turn knob to OFF,
wait 5 minutes, then repeat lighting procedure.

Sideburner Match Lighting

1. Turn on gas at LP tank.

2. Hold lit match to any port on
the burner.Push in and turn

sideburner knob to _. Be
sure burner lights and stays lit.

Before Your First Cookout

•Light burners,check to make sure they are lit, close the lid and
warm up grill on HIGH for 15 minutes. This curing of paint and

partswill produce an odor only on first lighting.

Burner Flame Check

•Light burner, rotate knobs from HIGH to LOW.You should see
a smaller flame in LOW position than seen on HIGH.Always

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

A Do not lean over grill while lighting.

1.Open lid during lighting.

2.Place match into match holder (hanging from side of cart).

3.Push in and turn left knob to Jl: HIGH position. Be sure
burner lights and stays lit.

4.Light right burner by pushing knob in and turning to _ HIGH
position.

Hose Check

•Beforeeach use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before using grill. Use only

valve/hose/regulator specified in the Parts List.

Normal Kinked
Hose Hose

Turning Grill Off

•Turn all knobs to OFF position. Turn LP tank off byturning
OPD handwheel clockwise to a full stop.

Iz l cAuT,o.Iz l

Ignitor Check

•Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heard and sparkseen each time between collector
box or burner and electrodes.See "Troubleshooting" if no click
or spark.

Valve Check

•Important: Make sure gas is off at LP tank before checking
valves. Knobs lock in OFF position. 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 LO position then turn back to OFF position.

Valves should turn smoothly.

General Grill Cleaning

•Keepthe outside of your grill looking new by cleaning it once a
month with warm soap and water ora non-abrasive cleaner. If
you don't havea grill cover, wipe off dust andgrime before
starting your grill.

• Coating the cooking gridswith spray-on cooking oil will keep the
food from sticking and makeclean up easier.After cooking,
scrape the grates with along handled, brass wire bristle brush.

•Check inside the grill bottom for grease build up and clean
often, especially after cooking fatty meat.

•Do not mistake brown or black accumulation of grease and
smoke for paint. Apply a strong solutionof detergent and water
or use a grill cleanerwith scrub brush on insides of grill lidand
bottom. Rinse and allow to completely air dry.Do not apply a

caustic grill/oven cleanerto painted surfaces.

•Plated wire grates: Washgrates with concentrated grill
cleaner or use soap and water solution. Dry thoroughly and

store indoors between cookouts.

• Plastic parts: Wash with warm soapy water and wipe dry.
,A. Do not use citrisol, abrasive cleaners, degreasers or a

concentrated grill cleaner on plastic parts. Damage to and
failure of partscan result.

•Porcelain grates: Because of glass-like composition, most
residue can be wiped away with baking soda/water solution or
specially formulated cleaner. Use non-abrasive 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.

SPIDER ALERT!

GAS COLLECTOR

VALVE AIR VENTURI

If you notice that your grill is getting hard to light or that the
flameisn't asstrong as it should be,take the time to checkand

clean the venturi's.

Insomeareasofthecountry,spidersor smallinsectshavebeen
knowntocreate"flashback"problems.Thespidersspinwebs,build

nestsandlay eggsin thegrill'sventuritube(s)obstructingtheflowof

gasto theburner.Thebacked-upgas canignitein theventuribehind
thecontrolpanel.Thisis knownasa flashbackanditcandamage

yourgrilland evencauseinjury.
Topreventflashbacksandensuregoodperformancetheburnerand

venturiassemblyshouldberemovedfromthe grilland cleaned

beforeusewheneverthegrillhas beenidleforanextendedperiod.

,,. j

SHUTTER

LIFTOUT

BURNERASSEMBLY

CLEAN OUT SPIDER WEBS

VENTURI INSIDEVENTURI

REMOVE
BURNER

CLIPS

•Stainless steel surfaces: Tomaintainyour grill's high quality
appearance, wash with mild detergent and warm soapy water
and wipe drywith a soft cloth after each use. Baked-on grease
deposits may require the use of an abrasive plastic cleaning
pad. Use only in direction of brushed finish toavoid damage.

Do not use abrasive pad on areas with graphics.

• Cooking surfaces: If a bristle brush isused 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.

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 grate and heattent.

3. Under grill remove grease cup, disconnect ignitorwire from

burner.

4. Inside grill remove burner assembly (A), clean ceramic

portion of electrode with rubbing alcohol and a swab.

5. Clean outside of burner with soap and water. Lay burner

upside down on flat surface, insertgarden hose to force
water through tubes. Make sure water comes out of all

burner holes. Open clogged holes with a thinwire. Shake
out excess water and examine holes. Due to normal wear

and corrosion some holes may become enlarged. Ifany
large cracks or holesare found replace burner.

6. If grill is to be stored, coat burner lightly with cooking oil.

Wrap in protective cover to keep insects out.

7. If notstoring grillafter cleaning, replace burner intogrill

bottom.

VERY IMPORTANT: Burner tubes must re-engage valve
openings, See illustration (A).

8. Reattach ignitor wire to electrode.

9. Reposition heat tent and cooking grate. Reattach clean

grease cup to grease clip.

10. Before cooking again on grill, perform a "Leak Test'and

"Burner Flame Check".

BurnerTube

Correctburner-to-valve engagement

Valve

B

10