Charbroil 463240613 Owner's Manual

PRODUCT GUIDE
MODEL 463240613

Char-Broil Modular Stove Top Cart

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 1-800-241-7548.

© 2013 Char-Broil, LLC Columbus, GA 31902

Printed in China

Assembly instructions © 2013

11/20/12 • G250-001-020801

TABLE OF CONTENTS

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

DANGER

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

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20

Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27

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

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

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

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

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.

INSTALLER/ASSEMBLER:

Leave this manual with consumer.

CONSUMER:

Keep this manual for future reference.

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

CAUTION

For residential use only. Do not use for commercial

For residential use only. Do not use for commercial

cooking.

CAUTION

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

CAUTION

Some parts may contain sharp edges.
Wear protective gloves if necessary.

THIS GRILL IS FOR OUTDOOR USE ONLY.

2

WARNING

CALIFORNIA PROPOSITION 65

1. Combustible by-products produced when using
this product contains chemicals known to the State
of California to cause cancer, birth defects, or
other reproductive harm.

2. This product contains chemicals, including lead
and lead compounds, known to the State of
California to cause cancer, birth defects or
other reproductive harm.

Wash your hands after handling this product.

CAUTION

Grease Fires

• 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 tank
off.

• If grill has not been regularly cleaned, a grease fire can
occur that may damage the product. Pay close attention
while preheating or burning off food residue to insure
that a grease fire does not develop. Follow instructions
on General Grill Cleaning and Cleaning The Burner
Assembly to prevent grease fires.

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.

• 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.

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.

• The best way to prevent grease fires is regular cleaning
of the grill.

NOTE: DO NOT over tighten screws and washers that

come into contact with porcelain coated surfaces. Over
tightening may cause the porcelain coating to crack and
break, resulting in exposed metal that will be prone to rust.

3

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 or

disconnect other retention means, then lift PL cylinder up and

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.

4

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.

Brush soapy solution onto areas indicated by arrows

in figure below.

▲ Do not use household cleaning agents. Damage to gas

train components can result.

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.

c

k

w

o

i

l

s

e

Strap and Cap

OPD Hand Wheel

Type 1 outlet with
thread on outside

Safety Relief Valve

C

f

f

O

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.

5

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
LP cylinder 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.

6

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.

Griddle Burner Ignitor Lighting

▲ Do not lean over griddle while lighting.

1. Turn burner control valve to the (OFF) position.

2. Turn ON gas at LP cylinder.

3. Open lid and leave open.

4. Turn the main burner control valve knob to the position .

5. Push and hold ELECTRONIC IGNITOR button the burner lights.
Verify burner flame through match lighting hole.

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.

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

WARNING: Top cover must be open when burner

is in operation.

7

WARNING

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

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.

Griddle Burner Match-Lighting

▲ Do not lean over grill while lighting.

1.Turn burner control valve to the (OFF) position.

2.Open lid and leave open. Turn ON gas at LP cylinder.

3.Place match into match holder (inside door.)

Light match, place into match lighting opening.

4.Push in and burner knob to position. Be sure
burner lights and stays lit. Verify burner flame through
match light opening.

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.

Match Light Opening

Stove Top burner Match Lighting

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

2. Open lid and leave open. Turn ON gas at LP cylinder.

3. Place match into match holder (inside door.)

Light match, place match near burner.

4.Turn burner knob to the (HIGH) position,
Be sure burner lights and stays lit.

5. If burner does not light, turn knob to the (OFF) position,

wait 5 minutes, then repeat lighting procedure.

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

Stove Top burner Ignitor Lighting

▲ Do not lean over grill while lighting.

1. Turn all burner control valve to the (OFF) position

2. Open lid and leave open. Turn ON gas at LP cylinder.

3. Turn burner knob to the (HIGH) position, push and hold

the ELECTRONIC IGNITOR button.

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

5. If burner does not light, turn knob to the (OFF) position,

wait 5 minutes, then repeat lighting procedure.

WARNING: Top cover must be open when burner

is in operation.

LOW position

Turning Griddle / Stove Top Off

• Turn all knobs to the OFFposition. 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.

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 stove top. Use only
valve/hose/regulator specified by manufacturer.

8

CAUTION

SPIDER ALERT!

SPIDER AND WEBS

INSIDE BURNER

If your griddle/stove top is getting hard to light
or the flame is weak, check and clean the
venturis and burners.

• 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 Griddle / Stove Top Burner

• Clean cooking grate / griddle.

• Store in dry location.

• When LP cylinder is connected to stove top, store outdoors in a
well ventilated space and out of reach of children.

• Cover stove top 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 the stove top.

General Griddle / Stove Top Burner 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.

9

Cleaning the Burner Assembly

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

1. Turn gas OFF at control knobs and LP cylinder.
Remove screws that hold orifice holder with the burner

2.
venturi. Figure A

Remove cooking grate.

3.

4.

Remove wing nuts from inside cart to disengage it.

Figure B

Carefully lift up the burner enough to expose the electrode

5.
wire.

Detach wire from electrode underneath the burner

Carefully take out the burner to clean. Figure C

6.
While cleaning, make sure that the ignitor wire is not bent

7.
or broken.

A

Burner Venturi

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.

(C) Wear eye protection: Use an air hose to force air into

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

Wire brush entire outer surface of burner to remove food

8.
residue and dirt.
Clean any blocked ports with a stiff wire such as an open

9.
paper clip.
Check burner for damage, due to normal wear and corrosion

10.
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.

View from under firebox

B

Remove three Wing Nuts
from inside cart

C

NOTE:

Remove

Screws

Correct

engagement

After cleaning put the burner back into the firebox and attach

12.
the electrode wire onto the electrode connector under the
burner.

13.

Place burner into position and reinstall the wing nuts.
Under the firebox, attach the orifice holder with the venturi tube.

14.
with the screws previous removed.

Replace the cooking grate.

15.

NOTE:

Reinstall

Screws

10