Charbroil 463612709 Owner's Manual

PRODUCT GUIDE
Kenmore Model No. 415.16121801 Kmart Item No. 640-174667113
IMPORTANT: Fill out the product record information below.
Serial Number
See rating label on grill for serial number.
Date Purchased
www.charbroil.com
If you have questions or need assistance during assembly, please call 1-800-241-7548.
Estimated assembly time: 35-40 minutes
The following are trademarks registered by W.C. Bradley Co. in the U.S. Patent and Trademark Office: Char-Broil®; America's Legendary Barbeque Company®; American Gourmet®; Bandera®; BrushHawg®; CB940®; Char-Diamonds®; Char-Broil Charcoal/Gas®; DiamondFlame®; Everybody Grills®; Everybody Outside®; FastStart®; Fireball®; Firenzy®; FlavorMaster®; Grill2Go®; Grill2Go® Express®; Grill Lovers®; H20 Smoker®; Keepers of the Flame®; New Braunfels Smoker Company®; Oklahoma Joe's®; Patio Bistro®; Patio Caddie®; Patio Kitchen®; Precision Flame®; Quantum®; Santa Fe®; Sear and Grill®; Sierra®; Signature Series®; The Big Easy®; The Minute Grill®; Trentino®; Wild West Tradition®; and the following marks:
® ®
The following are trademarks of W.C. Bradley Co.: Commercial Series™; Designer Series™; Grill2Go® Advantage™; Longhorn™; Double Chef™; QuickSet™; Ready When You Are™; Hog and Yard Bird™; You Bring the Party™; SureFire™; Universal Grill Parts™
TEC™ is a trademark of Tec Infrared Grills.
Protected under one or more of the following U.S. Patents: 4,989,579; 5,421,319; 5,458,309; 5,579,755; 5,996,573; 6,114,666; 6,135,104; 6,209,533; 6,279,566; 6,331,108; 6,484,900; 6,526,876; 6,595,197; 6,640,799; 6,640,803; 6,729,873; 6,739,473; 6,749,424; 6,863,100; 6,935,327; 6,951,213; 6792,935; 7,047,590; 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; D423,876; 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: 87,743; 87,744; 97,504; 99,355; 102,037; 104,200; 2,315,567; 2,336,036; France: 010,231; 010,422; 010,590; 010,849; 1,089,646; Germany: 1,089,646; South Korea: 384,565; China: 99,127,066.5; United Kingdom: 2,099,402; 1,089,646. Other Patents Pending. © 2008 W.C. Bradley Company
© 2008 Char-Broil, LLC Columbus, GA 31902
Printed in China
Assembly instructions © 2008
Model 463612509 10/29/08 80018033 463612709
TM REVISION 00
TABLE OF CONTENTS
For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
DANGER
Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Grilling Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-28
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-30
Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Safety Symbols
The symbols and boxes shown below explain what each heading means. Read and follow all 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.
2
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. 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, 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.
3
USE AND CARE
DANGER
DANGER
• NEVER store a spare LP cylinder under or near the appliance or in an enclosed area.
• Never fill a cylinder beyond 80% full.
• If the information in two points above is not followed exactly, a fire causing death or serious injury may occur.
LP Cylinder
•The LP cylinder used with your grill must meet the following requirements:
Use LP cylinders only with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.) capacity maximum.
•LP cylinders must be constructed and marked in accordance with specifications for LP cylinders of the U.S. Department of Transportation (DOT) or for Canada, CAN/CSA-B339, cylinders, spheres and tubes for transportation of dangerous goods. Transport Canada (TC). See LP cylinder collar for marking.
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
• 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.
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.
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.
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.
Straig
ht
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.
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.
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 bottom or back of grill.
Check burner flames regularly.
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
sBefore opening LP cylinder valve, check the coupling nut for
tightness.
sWhen grill is not in use, turn off all control knobs and LP
cylinder valve.
sIf the outdoor cooking gas appliance is not in use, the gas
must be turned off at the supply cylinder. Storage of an outdoor cooking gas appliance indoors is permissible only if the cylinder is disconnected and removed from the appliance.
sNever move grill while in operation or still hot.
sUse long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
sMaximum load for side shelves is 10 lbs.
sThe grease cup must be inserted into grease clip and
emptied after each use. Do not remove grease cup until grill has completely cooled.
s 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.
sIf 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.
sThe regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
sOnly use the pressure regulator and hose assembly supplied
with this grill. Replacement pressure regulator and hose assemblies must be specified or supplied by Char-Broil, LLC.
sIf you have a grill problem see the "Troubleshooting Section".
sIf 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 tank out of correct position specified in assembly instructions.
•Always close LP tank valve and remove coupling nut before moving LP tank from specified operation position.
CAUTION
• Putting out grease fires by closing the lid is not possible. Grills are well ventilated for safety reasons.
• Do not use water on a grease fire. Personal injury may result. If a grease fire develops, turn knobs and LP cylinder off.
• Do not leave grill unattended while preheating or burning off food residue on HI. If grill has not been regularly cleaned, a grease fire can occur that may damage the product.
7
Ignitor Lighting
s Do not lean over grill while lighting.
1.
Turn OFF gas burner control valves.
2.
Turn ON gas source or tank.
3.
Open lid during lighting.
4.
To ignite, turn left knob to HIGH.
5.
Push IGNITOR button rapidly.
6.If ignition does NOT occur in 5 seconds, turn the burner
controls OFF, wait 5 minutes and repeat the lighting procedure.
7. To ignite right burner, turn knob to . If ignitor does not work, follow match lighting instructions. After Lighting: Turn knobs to HI position for warm-up.
CAUTION
If burner does not light, turn knobs to OFF, wait 5 minutes, and try again. Always close valve during the 5 minute waiting period. If the burner does not ignite with the valve open, gas will continue to flow out of the burner and could accidentally ignite with risk of injury.
Match-Lighting
Sideburner Ignitor Lighting
1. Turn OFF gas burner control valves.
2. Turn ON gas source or tank.
3.
Turn sideburner knob to HI. and push IGNITOR button rapidly.
4. If sideburner does NOT light, turn knob to OFF,
wait 5 minutes, then repeat lighting procedure.
Sideburner Match Lighting
1.
Turn on gas at LP tank.
2. Hold lit match to any port on the burner. Push in and turn sideburner knob to . Be sure burner lights and stays lit.
Before Your First Cookout
•Light burners, check to make sure they are lit, close the lid and warm up grill on HIGH for 15 minutes. This curing of paint and parts will produce an odor only on first lighting.
Burner Flame Check
•Light burner, rotate knobs from HIGH to LOW. You should see a smaller flame in LOW position than seen on HIGH. Always check flame prior to each use. If only low flame is seen refer to "Sudden drop or low flame" in the Troubleshooting Section.
s Do not lean over grill while lighting.
1.Open lid during lighting.
2.Place match into match holder (hanging from side of cart).
3.Push in and turn left knob to HIGH position. Be sure
burner lights and stays lit.
4.Light right burner by pushing knob in and turning to HIGH position.
HI
LO
Hose Check
Before each use, check to see if hoses are cut, worn or kinked.
Replace damaged hoses before using grill. Use only valve/hose/regulator specified in the Parts List.
Normal Hose
Kinked Hose
8
Turning Grill Off
•Turn all knobs to OFF position. Turn LP tank off by turning
OPD hand wheel clockwise to a full stop.
Ignitor Check
•Turn gas off at LP tank. Press and hold ignitor button. "Click"
should be heard and spark seen each time between collector box or burner and electrodes. See "Troubleshooting" if no click or spark.
Valve Check
•Important: Make sure gas is off at LP tank before checking
valves. Knobs lock in OFF position. To check valves, first
push in knobs and release, knobs should spring back. If knobs do not spring back, replace valve assembly before using grill. Turn knobs to LO position then turn back to OFF position. Valves should turn smoothly.
General Grill Cleaning
•Keep the outside of your grill looking new by cleaning it once a
month with warm soap and water or a non-abrasive cleaner. If you don’t have a grill cover, wipe off dust and grime before starting your grill.
• Coating the cooking grids with spray-on cooking oil will keep the
food from sticking and make clean up easier. After cooking, scrape the grates with a long handled, brass wire bristle brush.
•Check inside the grill bottom for grease build up and clean
often, especially after cooking fatty meat.
•Do not mistake brown or black accumulation of grease and
smoke for paint. Apply a strong 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.
•Plated wire grates: Wash grates with concentrated grill
cleaner or use soap and water solution. Dry thoroughly and store indoors between cookouts.
Plastic parts: Wash with warm soapy water and wipe dry.
s Do not use citrisol, abrasive cleaners, degreasers or a concentrated grill cleaner on plastic parts. Damage to and failure of parts can result.
•Porcelain grates: Because of glass-like composition, most
residue can be wiped away with baking soda/water solution or specially formulated cleaner. Use non-abrasive scouring powder for stubborn stains.
•Painted surfaces: Wash with mild detergent or nonabrasive
cleaner and warm soapy water. Wipe dry with a soft nonabrasive cloth.
•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.
CAUTION
SPIDER ALERT!
GAS COLLECTOR
BOX & IGNITOR
CONTROL PANEL
VALVE
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.
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.
AIR
SHUTTER
LIFT OUT
BURNER ASSEMBLY
CLEAN OUT
VENTURI
VENTURI
INSIDE VENTURI
SPIDER WEBS
BURNER
REMOVE BURNER
CLIPS
SPIDER WEBS
INSIDE VENTURI
9
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. heat tent
Remove cooking grate and .
3.
Under grill remove grease cup, disconnect ignitor wire from burner.
4.
Inside grill remove burner assembly (A), clean ceramic portion of electrode with rubbing alcohol and a swab.
5.
Clean outside of burner with soap and water. Lay burner upside down on flat surface, insert garden hose to force water through tubes. Make sure water comes out of all burner holes. Open clogged holes with a thin wire. Shake out excess water and examine holes. Due to normal wear and corrosion some holes may become enlarged. If any large cracks or holes are found replace burner.
6.
If grill is to be stored, coat burner lightly with cooking oil. Wrap in protective cover to keep insects out.
7.
If not storing grill after cleaning, replace burner into grill bottom.
VERY IMPORTANT: Burner tubes must re-engage valve openings. See illustration (A).
8. electrode
Reattach ignitor wire to .
9. heat tent
Reposition and cooking grate. Reattach clean grease cup
10.
Before cooking again on grill, perform a “Leak Test” and “Burner Flame Check”.
to grease clip.
Burner Tube
Correct burner-to-valve engagement
A
Valve
B
10
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