Char-Broil 463240804 User Manual

463240804 • 80000327 • 10-16-03

WARNING

FOR YOUR SAFETY

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

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

FOR YOUR SAFETY
If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, immediately call your

gas supplier or your fire department.

Call Grill Service Center For Help And Parts

• If you need help or warranty parts call 1-800-241-7548 U.S. or
1-800-387-6057 CANADA, or send a FAX to 1-706-576-6355.
Business hours: Open 24 hours – Seven days a week.

• To order non-warranty replacement parts or accessories (

cover, cleaners, paint

1-706-565-2121.

IMPORTANT: Fill out the product record information below.

) call 1-800-993-2677 or send a FAX to

grill

Installation Safety Precautions

•

Use grill only with LP (propane) gas and the regulator/valve
assembly supplied.

•

Grill installation must conform with local codes, or in their
absence with

Z223.1 CAN/CGA-B149.2 Propane Installation Code

Handling and storage of LP cylinders must conform to LP Gas

NFPA/ANSI 58.

Code Grill is not for use in or on recreational
vehicles and/or boats.

• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or

National Electrical Code, ANSI / NFPA 70 Canadian
Electrical Code, CSA C22.1.

fuel supply hoses away from any hot surfaces.

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

Safety Symbols

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

National Fuel Gas Code, NFPA 54 / ANSI

or .

or

Keep any electrical cords and/or

DANGER

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

Model Number

Serial Number

See rating label on grill for serial number.

Date Purchased

CAUTION

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

WARNING

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.

WARNING

WARNING: Be alert to the possibility of serious bodily injury
if the instructions are not followed. Be sure to read and
carefully follow all of the messages.

CAUTION

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

2 • 463240804

TABLE OF CONTENTS WARRANTY

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

Grill Service Center...................................2

Product Record Information ............................2

Installation Safety Precautions ..........................2

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

Warranty ...........................................3

Parts List...........................................4

Parts Diagram.......................................5

Assembly ........................................6-15

Use and Care ...................................16-24

Manufacturer warrants to the original consumer­purchaser that this product shall be free from defects in
workmanship and materials under normal and reasonable
use and correct assembly (if assembled by consumer­purchaser), from date of purchase.

Brass burners - Lifetime
Stainless steel and die cast parts - 99 years
Electronic ignition - 10 years
Remaining parts - 2 years

Manufacturer will, at its option, refinish or replace any
product or part found to be defective during the warranty
period. Manufacturer will require you to return the part(s)
claimed to be defective, for its inspection, freight or postage
prepaid.

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

Consumer Warranty / P.O. Box 1240

Columbus, GA 31902-1240

Manufacturer may require reasonable proof of purchase
and we suggest you keep your receipt. In the state of
California only, if refinishing or replacement of the product is
not commercially practicable, the retailer selling this product
or 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 from which it
was purchased or to any retail establishment selling this
product in order to obtain performance under this warranty.

This warranty does not include the cost on any
inconvenience or property damage due to failure of the
product and does not cover damage due to misuse, abuse,
accident, damage arising out of transportation of the product,
or damage incurred through commercial use of the product.
This express warranty is the sole warranty given by the
manufacturer and is in lieu of all other warranties, express or
implied, including implied warranty of merchantability or
fitness for a particular purpose. Neither Manufacturer dealers
nor the retail establishment selling this product has any
authority to make any 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-purchaser. Some states do not allow the exclusion
or limitation of incidental or consequential damages. So the
above limitations or exclusions may not apply to you. This
warranty gives you specific legal rights and may also have
other rights which vary from state to state.

463240804 • 3

PARTS LIST – Model No. 463240804

Key Qty Description Part #

1 Grill Lid Assembly ...............80000301

A 1 Lid Insert........................80000302

B 1 Lid End Cap - Left ................80000303

C 1 Lid End Cap - Right ...............80000304

D 1 Lid Handle ......................80000305

E 1 Thermometer ....................80000096

F 1 Logo Plate ......................80000330

1 Grill Bottom Assembly............80000308

G 1 Grill Bottom Front Assembly.........80000651

H 1 Grill Bottom Rear Assembly .........80000018

I 1 Bottom End Cap - Left .............80000021

J 1 Bottom End Cap - Right ............80000022

K 3 Main Burner .....................80000349

L 1 Burner Brace/Carryover ............80000652

M 1 Ignitor Assembly ..................80000653

Key Qty Description Part #

1 Cart Assembly ..................80000065

Z 1 Cart Frame ......................80000661

AA 4 Caster Socket....................80000076

BB 1 Bottom Shelf.....................80000317

CC 1 Bottom Rail......................80000319

DD 1 Door Assembly - Left ..............80000320

EE 1 Door Assembly - Right .............80000323

FF 1 Grease Tray .....................80000251

GG 1 Door Brace ......................80000326

HH 1 SwingAway Warming Rack .........80000263

I I 1 Condiment Basket - Left............80000266

JJ 1 Condiment Basket - Right ..........80000267

KK 2 Locking Caster ...................80000268

LL 2 Fixed Caster.....................80000269

MM 1 Grease Cup .....................80000270

N 1 Manifold Heat Shield ..............80000031

O 1 Control Panel ....................80000314

P 4 Control Knob ....................80000035

Q 1 Manifold/Hose/Regulator Assembly . . . 80000036

1 Sideburner Shelf Assembly........80000315

R 1 Sideburner Frame ................80000045

S 1 Sideburner Lid ...................80000316

T 1 Sideburner Pan ..................80000051

U 1 Sideburner Electrode ..............80000055

V 1 Sideburner Control Panel...........80000056

W 1 Sideburner Assembly ..............80000277

1 Side Shelf Assembly .............80000059

X 1 Side Shelf.......................80000060

Y 1 Side Shelf Panel..................80000064

NN 1 Grease Clip .....................80000271

OO 2 Cooking Grate ...................80000293

PP 1 Sideburner Grate .................80000282

QQ 1 Sideburner Bezel .................80000034

RR 1 Caster Wrench ...................80000283

SS 1 AA Battery ......................80000284

TT 1 Match-Lighting Stick...............80000274

UU 1 Sideburner Valve Clip..............80000058

1 Hardware Pack...................80000666

1 Product Guide ...................80000327

Certified Grill Parts And Accessories®, Char-Broil and Design®, Char-Broil (Gas Grill Briquettes)®, Char-Diamonds®, Cooking Zone and Design®, Diamond Flame®, Executive Chef®, Faststart®, Flare
Fighter®, FlavorMaster®, Gas Grill Silouette and Design®, H2O Smoker®, Lava Flame®, MasterFlame®, MasterFlame Precision Cooking System®, PowerSpark®, Quantum®, VIP®, PrecisionFlame and
Design®, Sierra®, and TruFlame® are registered Trademarks of the W.C. Bradley Company. Thermos® is a registered trademark of the Thermos Company and its affiliates.

Artisan Collection by Char-Broil ™, C3 and Design™, Char-Broil and Design™, Flame Design™, FlavorTents™, Grill 2 Go™, Grillin’Stick™, Keeper of the Flame™, Keepers of the Flame™, Natural Grip™,
Outdoor Cooking Collection and Design™, Patio Bistro™, PrecisionFlame™, Pro-Check™, QuickSet Grills and Design™, SmokerTents™, The Big Easy™, The Minute Grill™, The Edge™, The Tuscan
Collection™, and The Urban Grill™ are Trademarks of the W.C. Bradley Company. Universal Grill Parts and Design™ is a trademark of the Thermos Company and its affiliates.

Protected under one or more of the following U.S. Patents: 4,598,692; 4,624,240; 4,747,391; 4,747,391; 4,817,583; 4,924,846; 4,989,579; 5,003,960; 5,076,256; 5,076,257; 5,090,398; 5,109,834; 5,224,676;
5,277,106; 5,421,319; 5,441,226; 5,452,707; 5,458,309; 5,566,606; 5,566,606; 5,579,755; 5,582,094; 5,613,486; 5,649,475; 5,706,797; 5,711,663; 5,765,543; 5,931,149; 5,996,573; 6,095,132; 6,135,104;
6,173,644B1; 6,279,566; 6,397,731; 6,418,923; 6,439,222; 6,523,461; D282,619; D339,714; D341,292; D343,337; D358,059; D361,466; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910;
D405,643; D405,643; D406,005; D406,009; D413,043; D413,229; D413,229; D414,982; D415,388; D416,164; D416,441; D416,441; D417,587; D422,516; D423,274; D423,876; D428,303; D435,396; D436,004;
D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D451,759; D456,202S; D460,313
and D461,359. Canada: 87743; 87744; 92607; 92608 and 1,316,424. Other Patents Pending.

4 • 463240804

PARTS DIAGRAM – Model No. 463240804

OO

A

C

E

B

F

H

D

HH

X

J

L

K

G

N

Y

PP

I

K

K

O

W

Q

P

P

FF

NN

S

M

SS

MM

R

U

GG

Z

KK

AA

T

V

AA

UU

QQ

LL

P

AA

LL

AA

RR

JJ

EE

TT

KK

BB

DD

CC

II

463240804 • 5

ASSEMBLY – Model No. 463240804

1

First

, remove door brace from rear legs. Place door
brace onto front legs as shown. Tabs on brace fit
inside legs. Secure brace to back of front legs using

4.2X10mm

one self-tap screw on each side.(WW)

Door brace

Rear view

Left front leg

Rear view

2

Attach , non-locking

locking casters to front legs

casters to rear legs. Tighten casters using the
caster wrench provided.

WW

Locking casters
on front legs.

6 • 463240804

Caster
wrench

3

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

Carefully lower the grill head onto the cart between the
two braces. Align the two holes on each side of the grill
head with the two holes on each brace. Make sure the
regulator hose is hanging outside the cart.

Align
holes

Regulator
hose

4

Secure grill head to leg braces using four screws ,

lock washers , and flat washers . Screws must

7mm (YY) 7mm (ZZ)

be attached from of grill head into brace.

Do not fully tighten screws until side shelf and sideburner
shelf are assembled.

inside

ZZ

YY

XX

1/4-20x3/4” (XX)

463240804 • 7

5

Place side shelf over right cart legs. Lip of shelf should fit between grill bottom and leg brace.
Secure shelf brackets to cart legs using one screw , lock washer ,
and flat washer on each bracket.

7mm (ZZ)

1/4-20x3/4” (XX) 7mm (YY)

CAUTION

SHARP EDGES! Wear gloves if necessary.

XX

6

Place sideburner shelf over left cart legs. Lip of shelf should fit between grill
bottom and leg brace. Secure shelf brackets to cart legs using one

1/4-20x3/4” (XX) 7mm (YY) 7mm (ZZ)

each bracket.

Fully tighten screws inside grill bottom at this time.

screw , lock washer , and flat washer on

CAUTION

SHARP EDGES! Wear gloves if necessary.

ZZ

Repeat on front bracket

YY

XX

YY

Repeat on front bracket

8 • 463240804

ZZ

7

Remove the two screws (M4x10mm) and washers (4mm) from the
sideburner valve bracket.

Place sideburner valve under front of sideburner control panel so that
valve stem comes through large hole. Place sideburner bezel over valve
stem. Secure bezel to panel and valve using the two screws and
washers you removed from the valve bracket. Press control knob onto
valve stem.

Valve stem

Sideburner bezel

First, remove
screws and
washers from
bracket.

Sideburner
valve

8

Insert sideburner into shelf, placing end of burner over
sideburner valve. Valve should be in center hole of burner
tube. Make sure pin on bottom of burner is in center hole
in shelf bracket. Secure burner to bracket with two

#10-24x3/8” (AAA) 5mm (BBB)

and flat washers .

5mm (CCC) See illustration below for

correct burner-to-valve engagement

screws , lock washers ,

.

Sideburner

CCC

BBB

AAA

Pin
in hole

Correct
burner-to-valve
engagement

Valve should be
in center hole in
burner tube.

463240804 • 9