Charbroil 463241004 Owner's Manual

463241004 • 80000484 • 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 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 • 463241004

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 ........................................6-16

Use and Care ...................................17-25

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.

463241004 • 3

PARTS LIST – Model No. 463241004

Key Qty Description Part #

1 Grill Lid Assembly ...............80000414

A 1 Lid Insert........................80000415

B 1 Lid End Cap - Left ................80000416

C 1 Lid End Cap - Right ...............80000417

D 1 Lid Handle ......................80000418

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

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

G 1 Foam Handle Grip ................80000784

1 Grill Bottom Assembly............80000422

H 1 Grill Bottom Front Assembly.........80000688

I 1 Lower Grill Bottom Rear Assembly....80000423

J 1 Upper Grill Bottom Rear............80000425

K 1 Bottom End Cap - Right ............80000428

L 1 Bottom End Cap - Left .............80000429

M 4 Main Burner .....................80000431

Key Qty Description Part #

1 Side Shelf Assembly .............80000456

BB 1 Side Shelf.......................80000457

CC 1 Side Shelf Panel..................80000459

1 Cart Assembly ..................80000461

DD 1 Cart Side Panel Left ...............80000462

EE 1 Cart Side Panel Right..............80000467

FF 1 Cart Back Panel ..................80000469

GG 4 Caster Socket....................80000076

HH 1 Bottom Shelf.....................80000470

I I 1 Bottom Rail......................80000472

JJ 1 Door Assembly - Left ..............80000476

KK 1 Door Assembly - Right .............80000479

LL 1 Door Brace ......................80000473

MM 1 Condiment Basket, Right ...........80000482

N 1 Burner Brace/Carryover ............80000689

O 1 Manifold Heat Shield ..............80000437

P 1 Ignitor System Assembly ...........80000690

Q 1 Control Panel ....................80000439

R 5 Control Knob ....................80000825

S 1 Manifold/Hose/Regulator Assembly . . . 80000440

T 1 Wind Reflector Baffle ..............80000829

1 Sideburner Shelf Assembly........80000446

U 1 Sideburner Frame ................80000447

V 1 Sideburner Lid ...................80000316

W 1 Sideburner Pan ..................80000051

X 1 Sideburner Electrode ..............80000055

Y 1 Sideburner Control Panel...........80000452

Z 2 Towel Bar .......................80000460

AA 1 Sideburner Assembly ..............80000453

NN 2 Locking Caster ...................80000268

OO 2 Fixed Caster.....................80000269

PP 1 Grease Tray .....................80000483

QQ 1 Grease Cup .....................80000270

RR 1 Grease Clip .....................80000271

SS 1 SwingAway Warming Rack .........80000421

TT 3 Cooking Grate ...................80000445

UU 1 Sideburner Grate .................80000282

VV 1 Match-Lighting Stick...............80000274

WW 5 Knob Bezel......................80000034

XX 1 Caster Wrench ...................80000283

YY 1 AA Battery ......................80000284

ZZ 1 Sideburner Valve Clip..............80000455

AAA 1 Condiment Basket, Left ............80000785

1 Hardware Pack...................80000701

1 Product Guide ...................80000484

4 • 463241004

PARTS DIAGRAM – Model No. 463241004

UU

A

F

E

C

B

TT

D

G

SS

J

I

T

K

BB

Z

V

L

N

M

CC

PP

M

X

O

W

AA

H

Q

U

S

R

P

Z

WW

Y

FF

P

R

YY

WW

WW

WW

VV

QQ

EE

RR

ZZ

DD

R

LL

GG

WW

GG

OO

NN

MM

GG

HH

OO

GG

II

XX

NN

AAA

KK

JJ

463241004 • 5

ASSEMBLY – Model No. 463241004

1

EEE

Assemble the two side panels to the bottom shelf using eight .

1/4-20x2-3/8” bolts (BBB)

Leg braces must face inward toward each other. Front legs have two holes on the back side
just above the side panel. Secure legs beneath shelf with eight ,

7mm lock washers (DDD) 1/4-20 hex nuts (EEE)

Right
rear leg

DDD

CCC

, and .

Braces face inward

Front leg

7mm flat washers (CCC)

Bottom shelf

No holes here

Holes here

Front

Front leg

2

Back panel

FFF

BBB

Assemble back panel between rear legs using four ,

lock washers (GGG) 5mm flat washers (HHH)

front legs using four .

, and . Attach door brace to back side of

4.2x10mm self-tap screws (III)

Rear view

Right
side
panel

Door
brace

#10-24x3/8” screws (FFF) 5mm

Back
panel

Tank hole to
left side.

Door
brace

6 • 463241004

Left
front

HHHGGG

III

leg

Tank hole to
left side.

3

Attach , non-locking

locking casters to front legs

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

Locking casters
on front legs.

4

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.

Caster
wrench

Regulator
hose

463241004 • 7

5

Secure grill head to leg braces using four ,

7mm lock washers (DDD) 7mm flat washers (CCC)

must be attached from of grill head into brace.

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

DDD

JJJ

, and . Screws

inside

CCC

1/4-20x3/4” screws (JJJ)

6

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 two ,

lock washers (DDD) 7mm flat washers (CCC)

, and on each bracket.

1/4-20x3/4” screws (JJJ) 7mm

Side shelf

CAUTION

SHARP EDGES! Wear gloves if necessary.

JJJ

CCC

DDD

8 • 463241004

Repeat on front bracket

7

JJJ

Repeat on front bracket

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 two ,

7mm lock washers (DDD) 7mm flat washers (CCC)

Fully tighten screws inside grill bottom at this time.

DDD

CCC

1/4-20x3/4” screws (JJJ)

, and on each bracket.

Sideburner
shelf

CAUTION

SHARP EDGES! Wear gloves if necessary.

8

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

First, remove
screws and
washers from
bracket.

Sideburner bezel

Sideburner
valve

463241004 • 9