Char-Broil 463222209 User Manual

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Page 1

PRODUCT GUIDE MODEL 463222209

IMPORTANT: Fill out the product record information below.

Serial Number

See rating label on grill for serial number.

Date Purchased

For support and to register your grill, please visit us at

www.charbroil.com

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

Estimated assembly time: 30 minutes

The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and T rademark Office: Caldera®; Charcoal2Go®; Char-Broil®; America's Legendary Barbeque Company®; American Gourmet®; Bandera®; Brush Hawg®; CB 940®; Char-Diamonds®; Char-Broil Charcoal/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™;Chef Tested™; Commercial Series™; Designer Series™;; Diamond Flame™; Double Chef™; Fireball™; Firenzy™; FlavorMaster™;Front Avenue™; Grill 2 Go® Advantage™; Hog and Y ard 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

Printed in China

10/19/09 • G528-001-070801

Page 2

TABLE OF CONTENTS

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

DANGER

Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-28

Troubleshooting..................................29-31

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Safety Symbols

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

WARNING

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.

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.

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

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

CAUTION

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

THIS GRILL IS FOR OUTDOOR USE ONLY.

CAUTION:

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

INSTALLER/ASSEMBLER:

Leave this manual with consumer.

CONSUMER:

Keep this manual for future reference.

WARNING:

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

CAUTION:

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

Page 3

WARNING

CAUTION

CALIFORNIA PROPOSITION 65

1. Combustion by-products produced 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. If your grill is Dual Fuel ready, 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 or Canadian Electrical Code, CSA C22.1. 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 and/or Canada only. Do not modify for use in any other location. Modification will result in a safety hazard.

Using pots larger than 6 quarts in capacity could exceed weight limit of the side burner shelf or side shelf, resulting in failure of grill cart components.

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.

Page 4

USE AND CARE

DANGER

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

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.

•LP cylinder valve must have:

•Type 1 outlet compatible with

regulator or grill.

•Safety relief valve.

•UL listed Overfill Protection

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.

OPD Hand Wheel

• 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 Valve

Safety Cap

Retainer Strap

LP cylinder in upright position for vapor withdrawal

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.

Page 5

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 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.

•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.

•Grill must be leak tested outdoors in a well-ventilated area,

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. in figure below.

s Do not use household cleaning agents. Damage to gas

train components can result.

Brush soapy solution onto areas indicated by arrows

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-wheel clockwise to a full stop.

4.Remove the protective cap from LP cylinder valve. Always use

cap and strap supplied with valve.

Strap and Cap

OPD Hand Wheel

Type 1 outlet with thread on outside

Safety Relief Valve

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

WARNING

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

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

Nipple has to be centered into the LP cylinder valve.

Page 6

Leak Testing Valves, Hose and Regulator

1.Turn all grill control knobs to OFF.

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-check feature 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!

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, or other similar

fittings on your grill.

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

• 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-contained LP 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.

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

NOTE: Your grill may NOT be equipped with a sideburner.

Page 7

WARNING

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

• 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, through viewing ports.

• Use grill only in well-ventilated space. 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.

Safety Tips

 Before opening LP cylinder valve, check the coupling nut for

tightness.

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

cylinder valve.

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

burns and splatters.

 Maximum load for sideburner and side shelf is 10 lbs.  The grease tray must be inserted into grill and emptied after

each use. Do not remove grease tray 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 recommended to 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. Determine the cause, correct it, then clean and inspect valve, hose and regulator before continuing. Perform a leak test.

 Keep ventilation openings in cylinder enclosure (grill cart) free

and clear of debris.

 Do 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.

 The regulator may make a humming or whistling noise during

operation. This will not affect safety or use of grill.

 If you have a grill problem see the "Troubleshooting Section".  If 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!

• 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-ignited gas 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.

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.

Main Burner Ignitor Lighting

 Do not lean over grill while lighting.  Light burners one at a time.

1. Turn all gas burner control valves to the OFF position.

2. Turn ON gas at LP cylinder.

3. Open lid during lighting.

4. To ignite any main burner, turn the main burner control valve knob to the HIGH position .

5. Push and hold ELECTRONIC IGNITOR button until the

burner lights. Verify burner flame through the viewing ports.

6. If Ignition does not occur in 5 seconds, turn the burner

controls to the OFF position, wait 5 minutes, and repeat the lighting procedure.

7. Ignite remaining burners by repeating steps 4 through 6

for each burner.

If ignition still not occur, follow match-lighting instructions.

Page 8

WARNING

Turn controls and gas source or tank OFF when not in use.

Sideburner Match Lighting

1. Turn all burner control valves

to the OFF position.

2. Open the sideburner lid. Turn ON gas at LP cylinder.

3.Place lit match near burner.

CAUTION

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.

Main Burner Match-Lighting

 Do not lean over grill while lighting.

1.Turn all burner control valves to the OFF position.

2.Open lid during lighting. Turn ON gas at LP cylinder.

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

Light match, place into lighting hole on top between emitter plate mounting brackets.

4.Push in and turn far right or far left knob to HI position. Be sure burner lights and stays lit. Verify burner flame through burner ports.

5.If ignition does NOT occur in 5 seconds, turn the burner control knob to OFF position, wait 5 minutes, and repeat the match lighting procedure

6. Ignite remaining burners by repeating steps 3 through 5 for each burner.

4.Turn sideburner knob to the HI position, Be sure burner lights and stays lit.

WARNING: Top cover must be open when sideburner(s)

is in operation.

Burner Flame Check

•Remove cooking grates and troughs. Light burners, rotate knobs from the HI position to the LOW position. You should

see a smaller flame in the LOW position than seen on the

HI position. 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.

HI position

LOW position

Turning Grill Off

•Turn all knobs to the OFF position. Turn LP cylinder off by turning hand-wheel clockwise 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 each collector box or burner and electrode. See "Troubleshooting" if no click or spark.

Emitter Plate Brackets

Sideburner Ignitor Lighting

 Do not lean over grill while lighting.

1. Turn all burner control valves to the OFF position

2. Open the sideburner lid. Turn ON gas at LP cylinder.

3. Turn SIDEBURNER knob to the HI position, push and hold

the ELECTRONIC IGNITOR button.

4. Once burner has ignited, turn knob to desired setting.

5. If sideburner does not light, turn knob to the OFF position, wait 5

minutes, then repeat lighting procedure.

Valve Check

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

position. Valves should turn smoothly.

OFF

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.

Page 9

CAUTION

SPIDER ALERT!

SPIDER AND WEBS

INSIDE BURNER TUBE

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.

CONTROL PANEL

VALVE

SPIDER WEBS

INSIDE VENTURI

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-up gas 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.

•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-on grease 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.

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 grease tray from back of grill.

3. Open doors, remove tank heat shield and grease pan from underneath the firebox.

4. Remove screws that hold orifice holder with the burner venturi. Figure A

5. Remove cooking grates and radiator plates. Remove hitch pin from front of the burner to disengage it.

Figure B

7. Carefully lift up the burner enough to expose the electrode

Detach wire from electrode underneath the burner

wire.

Carefully take out the burner to clean .Figure C While cleaning, make sure that the ignitor wire is not bent

or broken.

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.  Do not use citrisol, abrasive cleaners, degreasers or a

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

•Porcelain surfaces: Because of glass-like composition, 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.

Burner Venturi

View from under firebox

Front

Grill

Pull hitch pin from front of burner

Page 10

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 venturi 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 venturi tube several times.

the burner tube and out the burner ports. Check each port to make sure air comes out each hole.

Wire brush entire outer surface of burner to remove food

10.

residue and dirt. Clean any blocked ports with a stiff wire such as an open

11.

paper clip.

12.

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 venturi must be attached with orifice

holder properly. see illustration below.

Correct

engagement

13.

After cleaning put the burner back into the firebox and attach the electrode wire onto the electrode connector under the burner.

14.

Place burner into position and reinstall the hitch pin.

15.

Under the firebox, attach the orifice holder with the venturi tube. with the screws previous removed.

16.

Replace the grease pan, tank heat shield, greasy tray, radiator plate, and cooking grates.

NOTE:

Reinstall

Screws

Page 11

Grill Halogen Light

LIGHT OPERATION INSTRUCTIONS

1. Make sure light switch on the control panel is in the “OFF” position.

2. Connect light plug to an extension cord, then put the extension cord plug into the outlet on the wall.

3. Turn the light switch to “ON”.

OFF

Light plug

WARNING

Keep any electrical supply cord away from any heated surface. Use the shortest length extension cord required. Do not connect 2 or more extension cords together.

Bulb Replacement

Make sure light switch on the control panel is in the “OFF” position and adapter plug is disconnected from outlet.

Step 1

Step 2

Step 3

OFF

Extension cord, for out door use

Release the screw securing the light socket.

Step 4

Pull out the bulb and replace with a new bulb.

Take out the socket and remove the lens.

Loosen the two screws which are locking the bulb.

Step 5

Reverse instructions from step 3 through step 1 to re-install socket.

CAUTION

Take care not to touch the bulb with your bare fingers. Touching bulb with your skin can leave a film on the bulb that causes it to burn out quickly.

Bulb Specification

Bulb Type: Halogen Wattage: 10 W per bulb Voltage: 12 V

Page 12

Cleaning the Lens

1. Prior to cleaning, make sure the light switch is in the “OFF” position and the light plug is disconnected from the power supply.

2. Do not clean the glass lens when warm. Allow to cool before cleaning. Sudden change in temperature may cause cracking of the glass lens.

3. Use a damp towel to clean the surface of the glass lens.

4. Allow the lens to dry before reconnecting the light plug to the power supply and turning the light switch to the “ON” position.

IMPORTANT

• Since 1971 the National Electric Code (NEC) has required Ground Fault Interrupter devices on all outdoor circuits.

• If your residence was built before 1971, check with a qualified electrician to determine if a Ground Fault Interrupter protector exists.

• Do not use this appliance if the circuit does not have GFI protection.

• Do not plug this appliance into an indoor circuit.

WARNING

1. To protect against electric shock, do not immerse cord or plugs in water or other liquid.

2. Unplug from the outlet when not in use and before cleaning. Allow to cool before putting on or taking off parts.

3. Do not operate grill with a damaged cord, plug, or after the appliance malfunctions or has been damaged in any manner.

4. Do not let the cord hang over the edge of a table or touch hot surfaces.

5. Do not use an outdoor cooking gas appliance for purposes other than intended.

6. When connecting, first connect plug to the outdoor cooking gas appliance then plug appliance into the outlet.

7. Use only a Ground Fault Interrupter(GFI) protected circuit with this outdoor cooking gas appliance.

8. Never remove the grounding plug or use with an adapter of 2 prongs.

9. Use only extension cords with a 3 prong grounding plug, rated for the power of the equipment, and approved for outdoor use with a W-A marking.

Page 13

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 freight pre-paid by the consumer for review and examination.

SCOPE OF COVERAGE PERIOD OF COVERAGE TYPE OF FAILURE COVERAGE

Stainless Burner Firebox and Lid All Other Parts

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

The original consumer-purchaser will 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.

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

RUST is not considered a manufacturing or materials defect.

Limited Lifetime 2 years from date of purchase* 1 year from date of purchase*

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-family household 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. In the event of parts availability issues, the manufacturer reserves the right to substitute like or similar parts that are equally functional.

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-purchaser prior 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.

PERFORATION, MANUFACTURING, AND MATERIAL DEFECTS ONLY

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.

Page 14

PARTS LIST

Key Qty Description

A 2 LOCKING CASTER

B 2 FIXED CASTER

C 1 BOTTOM SHELF

D 2 DOOR MAGNET ASSEMBLY

E 1 LEFT SIDE CART PANEL

F 1 RIGHT SIDE CART PANEL

G 1 LOWER BACK CART PANEL

H 1 12 VOLT ADAPTER

I 1 GROMMET, F/ HOSE, SMALL

J 1 GROMMET, F/ HOSE, LARGE

K 1 FIREBOX

LEFT OUTER SIDE PANEL, F/ FIREBOX

RIGHT OUTER SIDE PANEL, F/ FIREBOX

N 1 FIREBOX UPPER PANEL

O 2 HOSE CLIPS

HEAT SHIELD, F/ CONTROL PANEL

Q 1 MATCH HOLDER

R 3 MAIN BURNER

ELECTRODE, W/O WIRE, F/ MAIN BURNER

T 1 IGNITER SWITCH MODULE

U1LIGHT SWITCH

V 1 HALOGEN LIGHT ASSEMBLY

W 2 COVER BOX, F/ LIGHT

X 1 HOSE VALVE REGULATOR

Y 1 CONTROL PANEL, TOP

Z 1 CONTROL PANEL, BOTTOM

AA 2 PIN, F/ DOOR

BB 4 BEZEL, F/ CONTROL KNOB

CC 4 CONTROL KNOB

DD 1 GREASE PAN, F/ FIREBOX

EE 1 TOP LID

FF 1 TOP LID HANDLE

GG 1 LEFT HEAT SHIELD, F/ TOP LID

HH 1 RIGHT HEAT SHIELD, F/ TOP LID

II 1 INNER INSERT, F/ TOP LID

JJ 4 RUBBER BUMPER, ROUND

KK 2

RUBBER BUMPER, RECTANGULAR, F/ LID

LL 1 LOGO PLATE

MM 1

HARDWARE F/ TOP LID ASSEMBLY

NN 1 FRONT BRACE

OO 1 RIGHT SIDE SHELF

PP 1 SKIRT, RIGHT SHELF

QQ 1 TOWEL BAR

Key Qty Description

RR 1 LEFT SIDE SHELF, SIDEBURNER

SS 1

UPPER FASCIA (SKIRT), F/ LEFT SHELF

TT 1

LOWER FASCIA W/ ART, F/ LEFT SIDE SHELF

UU 1 DRIP PAN, F/ SIDE BURNER

VV 1 LID, F/ SIDE BURNER

WW 1 CART UPPER BACK PANEL

XX 1 DEBRIS COLLECTOR PANEL

YY 1 SIDEBURNER

ZZ 1 ELECTRODE, F/ SIDEBURNER

AAA 1

ELECTRODE WIRE, F/ SIDEBURNER

BBB 1 SIDEBURNER GRATE

CCC 1 HEAT SHIELD, F/ TANK,

DDD 1 LEFT DOOR, NO HANDLE

EEE 2 DOOR HANDLE

FFF 1 RIGHT DOOR, NO HANDLE

GGG 1 ELECTRONIC IGNITION MODULE

HHH 1

HEAT SHIELD, F/ ELECTRONIC IGNITION MODULE

III 1

CAP, F/ ELECTRONIC IGNITION MODULE

JJJ 1 CONDIMENT TRAY

KKK 2 DIVIDER PANEL

LLL 3 EMITTER PLATE

MMM 3

FRONT MOUNTED TEMPERATURE GAUGE

NNN 3 COOKING GRATE, MAIN

OOO 1 WARMING RACK

PPP 1

CYLINDER SCREW F/ TANK SECURE

QQQ 1 GREASE TRAY

Key Qty Description

… 1 CASTER WRENCH

… 1 HARDWARE PACK

… 1 ASSEMBLY MANUAL, ENGLISH

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

NOT Pictured

Page 15

PARTS DIAGRAM

NNN

LLL

OOO

KKK

EEE

S S

QQQ

III

GGG

CCC

EEE

MMM

JJJ

BBB

AAA

DDD

HHH

PPP

FFF

Page 16

ASSEMBLY

Screw in the two locking casters at the rear of the bottom shelf and the two fixed casters at the front, and tighten

with the caster wrench provided.

Locking caster

Fixed caster

Front

Bottom shelf

Make sure side panels are pushed as far to the rear of bottom shelf as possible before fully tightening screws.

Attach side panels to bottom shelf using three

1/4-20x1/2” screws, 7mm lock washers per panel. IMPORTANT: Panel with hole must

be on left side of bottom shelf.

Left side panel (with hole)

Rear

1/4-20x1/2” screw

Qty.6

7mm lock washer

Qty.6

1/4-20x1/2” screw

7mm lock washer

Right side panel

Page 17

Attach light adapter to back panel using four #8-32x3/8” screws, 4mm lock washers, 4mm flat washers and #8 nuts, shown A.

Place lower back panel between side panels at rear of bottom shelf. Secure lower back panel to side panels using two

1/4-20x1/2” screws and 7mm lock washers each side. Secure lower back panel to bottom shelf using one 1/4-20x1/2”

screw and 7mm lock washer, shown B.

#8-32x3/8” screw

Qty.4

4mm lock washer Qty.4

4mm flat washer

Qty.4

#8 Nut

Qty.4

#8 Nut

Adapter

1/4-20x1/2” Qty.5

7mm

lock washer

Qty.5

4mm flat

washer

screw

4mm lock

washer

#8-32x3/8”

screw

7mm

lock washer

1/4-20x1/2”

screw

Adapter

Lower back panel

1/4-20x1/2”

screw

7mm

lock washer

This step requires two people to lift and position grill head onto cart.

head onto the cart, aligning slots at bottom of grill head with posts on cart side panels. Make sure the

regulator hose is hanging inside the cart. Grill head must face open side of cart.

Carefully lower the grill

Grill head

Regulator hose

Page 18

Insert front brace under control panel and between cart side panels. Secure using two

1/4-20x1½”

screws, 7mm lock washers on each side.

1/4-20x1½”

Qty.4

Control Panel

Front Brace

Remove the two screws and washers that are attached on right side of firebox front, shown A.

Insert flange on right side shelf into side shelf brackets on side of firebox, shown B.

Attach right side shelf front using the two screws and washers which were removed from right side of fire box, shown C. Attach rear of shelf using one 1/4”-20x1/2” screw and 7mm lock washer, shown D.

screw

7mm Lock

Washer

7mm Lock Qty.4

1/4-20x1½”

Screw

washer

1/4-20x1/2” Qty.1

7mm lock

Qty.1

Screw

washer

remove

Screw

Washer

*Screws and washers removed from right side of firebox front.

Side shelf bracket

7mm lock

Washer

Right side shelf

1/4-20x1/2”

Screw

Page 19

Attach left side lower fascia to left side upper fascia using three #10x3/8” screws, 5mm lock washers and 5mm flat washers, shown A.

Remove the three screws and washers that are attached on left side of firebox front, shown B. Insert flange on left side shelf into side shelf brackets on side of firebox, shown C.

Attach front of side shelf using the three screws and washers which were removed from left side of firebox front, shown D. Attach rear of shelf using one

1/4-20x1/2”

screw and, 7mm

lock washer, shown E.

Inside of left side shelf

Left side lower fascia (inside)

remove

5mm flat washer

5mm lock washer

#10x3/8” screw

Qty.3

5mm lock washer Qty.3

5mm flat washer Qty.3

1/4-20x1/2” Qty.1

7mm lock

Qty.1

Screw

washer

*Screws and washers removed from left side of firebox front.

screw

1/4-20x1/2”

screw

Left side shelf

Left side upper fascia

7mm lock

washer

Side shelf

bracket

Page 20

Attach debris collector panel to upper back panel using four #10x3/8” screws, 5mm flat washers, 5mm lock washers, and #10 nuts, shown A.

On back of grill, place upper back panel between side panels and above lower back panel. Secure upper back panel, in

lower holes, using one

1/4-20x1½”

screw and 7mm lock washer on each side. In upper holes, use one

1/4-20x1½”

screw and 7mm lock washer on each side, shown B. on the cart, secure upper back panel to lower back panel using one 1/4-20x1/2” screw and 7mm lock washer, shown C.

#10x3/8” screw

Qty.4

#10x3/8” screw

5mm flat washer

5mm lock washer

#10 Nut

5mm lock washer

Qty.4

5mm flat washer Qty.4

SIDE VIEW

#10 Nut Qty.4

Debris collecter panel

1/4-20x1½”

Qty.4

screw

1/4-20x1/2” Qty.1

Screw

7mm Lock Qty.5

Upper back panel

washer

Upper back panel

Lower back panel

Upper back panel

7mm

lock washer

1/4-20x1½”

screw

Upper back panel

7mm

lock washer

7mm

lock washer

1/4-20x1½”

1/4-20x1/2”

screw

Page 21

First, remove the two screws and lock washers already attached to the sideburner valve bracket. Position sideburner valve bracket beneath sideburner shelf fascia so that valve stem comes through larger center hole in fascia. Align the holes on valve bracket with left and right holes on fascia. Secure using lock washers and screws that were removed from bracket. Next, place sideburner bezel over valve stem on front side of fascia. Align small holes on bezel with upper and lower holes on fascia. Attach using two #8-32x3/8” screws and 4mm lock washers. Press sideburner control knob onto valve stem.

Lock washer

Screw

Valve stem

Screws and Washers removed from valve bracket

Insert sideburner burner into left shelf.

shelf, shown A.

sideburner valve, shown C.

#8-32x3/8” screw Qty.2

Control knob bezel

Sideburner

valve bracket

The stud on bottom of burner

Secure burner to sideburner drip pan with one Wing nut, shown B.

Wing nut

Qty.1

4mm lock washer Qty.2

Sideburner shelf fascia

fits into rear small hole in sideburner drip pan on

Note: Use upper and lower

holes on fascia to

attach bezel

Valve stem

4mm

lock washer

#8-32x3/8” screw

Sideburner control knob

Make sure burner tube engages

Wing nut

Burner tube

Sideburner burner

Sideburner drip pan

Valve

Page 22

Under sideburner shelf, attach sideburner ignitor wire to electrode, shown A. Place sideburner grate onto sideburner shelf, aligning grate legs with holes in shelf, shown B.

Sideburner Ignitor Wire

Electrode

Sideburner grate

Inside the cart left, connect the adapter wire harnesses to the light wire harnesses as shown.

Light wire harness

Adapter wire harness

Lower back panel (Inside)

Adapter

Page 23

Inside of cart, insert rear shield tabs into slots next to grease tray opening on upper back panel, shown A.

Attach front shield tabs(with holes) under front brace with two #8x3/8” self-tapping screws, shown B.

#8x3/8”

self-tapping screw

Rear

Qty. 2

Upper back panel

front tab (w/hole)

Insert hinge pin on bottom of doors into hole in bottom shelf. Press upper hinge pin in front brace, align hinge hole on top of door, and release hinge pin into door.

Front

rear tab

Tank heat shield

Grease tray opening

#8x3/8”

self-tapping screw

Tank heat shield

Cart lower back panel

Note: some parts omitted

for clarity of illustration

Front Brace

Left door

PRESS

Top of door

Right door

Hinge pin on bottom of door

Page 24

Release the cap and nut from electronic ignition module. Attach electronic ignition module and heat shield to the cart left side panel with the nut, shown A.

Insert AA battery into ignition module, negative (

Connect each of the wires from the main burner electrodes, and sideburner electrode into the back of the Electronic Ignition

Module. Total (4) connections.

Connect the two wires [(a) and (b)] from Total (2) connections.

NOTE: Switch

terminals are larger than electrode

the switch wiring harness into the back

-) end first. Then put on the cap, shown B.

of the Electronic Ignition Module.

terminals and should only be

installed in location shown as (a),(b).

Left side panel

Nut

Heat shield

Place the Condiment Basket on the right door inside; make sure to insert the legs of the Condiment Basket into the

brackets which were attached on the door inside shown as below.

AA batteryCap

Electronic

ignition module

(a)

2 3

(b)

Bracket

Condiment basket

Page 25

Put divider panels between burners, shown A. Secure divider panels to firebox front using two #8x3/8” self-tapping screws, shown B.

Secure divider panels to firebox rear using two #8x3/8” self-tapping screws, shown C.

#8x3/8”

Qty. 4

self-tapping screw

Firebox rear

Divider panel

Firebox front

#8x3/8”

self-tapping screw

#8x3/8”

self-tapping screw

#8x3/8”

self-tapping screw

Firebox front

Firebox rear

Divider panel

#8x3/8”

self-tapping screw

Page 26

Place Emitter plates in the firebox.

Emitter Plates

Insert temperature gauge stem into the bigger hole on the black panel,shown A.

Make sure the gauge is pushed in as far as it will go, then push the gauge downward until it clips into the panel, as shown

in B/C.

Note: Some parts omitted for

clarity of illustration

Temperature gauge stem

Back of the panel

Knob bezel

Control panel

Temperature gauge

Page 27

Place cooking grates onto the firebox as shown. Make sure to put taller end at rear of fire box.

Rear of grate

Rear of fire box

Cooking grate

Insert the two wire ends at rear of warming rack into holes in back of

Front wires of warming rack rest on sides of firebox.

firebox.

Warming rack

Assembled warming rack

Page 28

LP CYLINDER IS SOLD SEPARATELY. Fill and leak check the cylinder before attaching to grill and regulator (see Use &

Cylinder screw at rear of cart

Always keep LP cylinders in upright position during use, transport, and storage.

Care section). Once cylinder has been filled and leak checked, place cylinder into hole in bottom shelf. Make sure cylinder valve is facing front of grill. Secure cylinder with cylinder screw under bottom shelf. Perform Burner Flame Check.

See Use & Care section of this manual to perform the “Burner Flame Check” and for important safety instructions before using.

Cylinder screw

CAUTION

LP Cylinder

(not included)

Cylinder valve must face to front of cart once tank is attached. Failure to install cylinder correctly may allow gas hose to be damaged in operation, resulting in the risk of fire.

On back of grill, slide grease tray into opening in upper back panel.

Regulator

CAUTION

Failure to install grease tray will cause hot grease to drip from bottom of grill with risk of fire or property damage.

Grease tray

Page 29

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

Emergencies

Gas leaking from cracked/cut/burned hose.

Gas leaking from LP cylinder.

Gas leaking from LP cylinder valve.

Gas leaking between LP cylinder and regulator connection.

Fire coming through control panel.

Grease fire or continuous excessive flames above cooking surface.

Troubleshooting

Problem

Possible Cause

• Damaged hose.

• Mechanical failure due to rusting or mishandling.

• Failure of cylinder valve from mishandling or mechanical failure.

• Improper installation, connection not tight, failure of rubber seal.

• Fire in burner tube section of burner due to blockage.

• Too much grease buildup in burner area.

Possible Cause

Prevention/Solution

• Turn off gas at LP cylinder or at source on natural gas systems. If anything but burned, replace valve/hose/regulator. If burned, discontinue use of product until a plumber has investigated cause and corrections are made.

• Replace LP cylinder.

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

• Turn off LP cylinder valve. Remove regulator from cylinder and visually inspect rubber seal for damage. See LP Cylinder Leak Test and Connecting Regulator to the LP Cylinder.

• Turn off control knobs and LP cylinder valve. Leave lid open to allow flames to die down. After fire is out and grill is cold, remove burner and inspect for spider nests or rust. See Natural Hazard and Cleaning the Burner Assembly pages.

• Turn off control knobs and LP cylinder valve. Leave lid open to allow flames to die down. After cooling, clean food particles and excess grease from inside firebox area, grease tray, and other surfaces.

Prevention/Solution

Burner(s) will not light using ignitor. (See Electronic Ignition Troubleshooting also)

Continued on next page.

GAS ISSUES:

• Trying to light wrong burner.

• Burner not engaged with control valve.

• 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.

• See instructions on control panel and in Use and Care section.

• Make sure valves are positioned inside of burner tubes.

• Ensure burner tubes are 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.”

• For a grill equipped with the AUTO-CLEAN™ feature, make sure the AUTO-CLEAN™ valve is set to “Grill”

• Turn off knobs and disconnect coupling nut from LP cylinder. Reconnect and retry.

• Turn the coupling nut approximately one-half to three-quarters additional turn until solid stop. Tighten by hand only - do not use tools.

• Replace electrode(s).

Main Burners:

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

Sideburner:

• Tip of electrode should be pointing toward gas port opening on burner. the distance should be 1/8” to 3/16”. Adjust if necessary.

• Wire and/or electrode covered with cooking residue.

• Wires are loose or disconnected.

• Wires are shorting (sparking) between ignitor and electrode.

• Dead battery.

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

• Reconnect wires or replace electrode/wire assembly.

• Replace ignitor wire/electrode assembly.

• Replace with a new AA-size alkaline battery.

Page 30

Troubleshooting (continued)

Problem

Burner(s) will not light using ignitor. (See Electronic Ignition Troubleshooting also)

Burner(s) will not match light.

Sudden drop in gas flow or low flame.

Flames blow out.

Possible Cause

ELECTRONIC IGNITION:

• No spark, no ignition noise.

• No spark, some ignition noise.

• Sparks, but not at electrode or at full strength.

• See “GAS ISSUES:” on previous page.

• Match will not reach.

• Improper method of match-lighting.

• Out of gas.

• Excess flow valve tripped.

• Vapor lock at coupling nut/LP cylinder connection.

• High or gusting winds.

• Low on LP gas.

Prevention/Solution

• See Section I of Electronic Ignition System.

• See Section II of Electronic Ignition System.

• See Section III of Electronic Ignition System.

• Use long-stem match (fireplace match).

• See “Match-Lighting” section of Use and Care.

• Check for gas in LP cylinder.

• Turn off knobs, wait 30 seconds and light grill. If flames are still low, turn off knobs and LP cylinder valve. Disconnect regulator. Reconnect regulator and leak-test. Turn on LP cylinder valve, wait 30 seconds and then light grill.

• Turn off knobs and LP cylinder valve. Disconnect coupling nut from cylinder. Reconnect and retry.

• Turn front of grill to face wind or increase flame height.

• Refill LP cylinder.

Flare-up.

Persistent grease fire.

Flashback... (fire in burner tube(s)).

Unable to fill LP cylinder.

One burner does not light from other burner(s).

AUTO-CLEAN™

(If Equipped)

Timer does not work (Green light does not flash)

• Excess flow valve tripped.

• Grease buildup.

• Excessive fat in meat.

• Excessive cooking temperature.

• Grease trapped by food buildup around burner system.

• Burner and/or burner tubes are blocked.

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

• Clean burners and inside of grill/firebox.

• Trim fat from meat before grilling.

• Adjust (lower) temperature accordingly.

• Turn knobs to OFF. Turn gas off at LP cylinder. Leave lid in position and let fire burn out. After grill cools, remove and clean all parts.

• Turn knobs to OFF. Clean burner and/or burner tubes. See burner cleaning section of Use and Care.

• Some dealers have older fill nozzles with worn threads.

• Grease buildup or food particles in

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

• Clean carry-over tube(s) with wire brush.

end(s) of carryover tube(s).

Possible Cause Prevention/Solution

Dead Battery Batteries installed incorrectly. Knob Position did not start the Clean

Cycle

Replace Batteries Install batteries correctly. Push Knob in to start the clean cycle. (Green LED should begin to

flash)

No LED’s will illuminate Dead Battery

Red LED next to battery

Low Battery Strength

symbol is illuminated

Replace Batteries

Prepare to replace batteries (NOTE: Clean cycle will operate with

a weak battery.

Page 31

Troubleshooting - Electronic Ignition

Problem (Ignition)

SECTION I

No sparks appear at any electrodes when Electronic Ignition Button is pressed; no noise can

be heard from spark

module.

SECTION II

No sparks appear at any electrodes when Electronic Ignition Button is pressed; noise can

be heard from spark

module.

Possible Cause

• Battery not installed properly.

• Dead battery.

• Button assembly not installed properly.

• Faulty spark module.

• Output lead connections not connected.

Check Procedure

• Check battery orientation.

• Has battery been used previously?

• Check to insure threads are properly engaged. Button should travel up and down without binding.

• If no sparks are generated with new battery and good wire connections, module is faulty.

• Are output connections on and tight?

Prevention/Solution

• Install battery (make sure that “+” and “–” connectors are oriented correctly, with “+” end up and “–” end down.)

• Replace battery with new AA-size alkaline battery.

• Unscrew button cap assembly and reinstall, making sure threads are aligned and engaged fully.

• Replace spark module assembly.

• Remove and reconnect all output connections at module and electrodes.

SECTION III

Sparks are present but not at all electrodes and/or not at full strength

• Output lead connections not connected.

• Arcing to grill away from burner(s).

• Weak battery.

• Electrodes are wet.

• Electrodes cracked or broken “sparks at crack”.

• Are output connections on and tight?

• If possible, observe grill in dark location. Operate ignition system and look for arcing between output wires and grill frame.

• All sparks present but weak or at slow rate.

• Has moisture accumulated on electrode and/or in burner ports?

• Inspect electrodes for cracks.

• Remove and reconnect all output connections at module and electrodes.

• If sparks are observed other than from burner(s), wire insulation may be damaged. Replace wires.

• Replace battery with a new AA-size alkaline battery.

• Use paper towel to remove moisture.

• Replace cracked or broken electrodes.

Page 32

NOTES

Page 33

NOTES

Page 34

NOTES

Page 35

Warranty Registration Department P.O. Box 1240 Columbus, GA 31902-1240

Page 36

Char-Broil 463222209 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual