Charbroil 463721108 Owner's Manual
MODEL 415.16108 810983-114 • PRODUCT GUIDE• 640-
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.
If you have any questions or need assistance during assembly, please call 1-800-241-7548.
To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com
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.
Printed in China • 463721108 • 463721308 • 80013232 • 09-27-07
DANGER
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.
Call Grill Service Center for Help and Parts
• If you need assistance with your product or warranty parts call
1-800-241-7548. Hours of Service Center Operation are
8:00 A.M. To 6:00 P.M. EST Monday - Friday.
• To order non-warranty replacement parts or accessories
please visit us on the web at www.charbroil. com or call
1-800-241-7548 and one of our friendly and knowledgeable
agents will be glad to assist you.
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 National Fuel Gas Code, NFPA 54 / ANSI
Z223.1 and Natural Gas and Propane Installation Code,
CSA B149.1. Handling and storage of LP cylinders must
conform to LP Gas Code NFPA/ANSI 58. 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 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
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.
Safety Symbols
The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.
IMPORTANT: Fill out the product record information below.
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.
2 • 463721108 • 463721308
DANGER
DANGER: Indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
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.
TABLE OF CONTENTS
For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Grill Service Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
To insure your satisfaction
and for follow-up service,
register your grill
online at:
www.grillregistration.com
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.
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; 6,935,327; 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, D461,359 and D504,048. Canada: 87743; 87744; 92607; 92608 and 1,316,424. Other Patents Pending. Assembly instructions © 2006.
463721108 • 463721308 • 3
USE AND CARE
DANGER
LP Tank
• The LP tank used with your grill must meet the following
requirements:
• Use LP tanks only with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.
• NEVER store a spare LP tank under or near grill or in
enclosed areas
• Never fill the cylinder beyond 80% full.
• An overfilled or improperly stored tank is a hazard due
to possible gas release from the safety relief valve.
• If you see, smell or hear escaping gas, immediately get
away from the LP tank/grill and call your fire
department.
• If the above is not followed exactly, a fire causing
death or serious injury may occur.
• LP tanks must be constructed and marked in accordance with
specifications for LP tank 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 tank collar for marking.
• LP tank 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 tanks equipped with this type of valve.
• LP tank must be arranged for vapor withdrawal and include
collar to protect LP tank valve.
LP cylinder in upright position for vapor withdrawal
OPD Hand Wheel
LP Tank Removal, Transport And Storage
• Turn OFF all control knobs and LP tank valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Lift LP tank wire upward off of LP tank collar, then
lift LP tank up and off of support bracket. Install safety cap onto
LP tank 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.
LP Tank Valve
Safety Cap
Retainer Strap
• A disconnected LP tank in storage or being transported must
have a safety cap installed (as shown). Do not store an LP tank
in enclosed spaces such as a carport, garage, porch, covered
patio or other building. Never leave an LP tank inside a vehicle
which may become overheated by the sun.
• Do not store an LP tank in an area where children play.
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 Tank Filling
• Use only licensed and experienced dealers.
• LP dealer must purge tank before filling.
• Dealer should NEVER fill LP tank more than 80% of LP tank
volume. Volume of propane in tank will vary by temperature.
• A frosty regulator indicates gas overfill. Immediately close LP
tank 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 tank, 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 • 463721108 • 463721308
LP Tank Exchange
Connecting Regulator To The LP Tank
• Many retailers that sell grills offer you the option of replacing
your empty LP tank through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
test and certify their cylinders. Exchange your tank only for
an OPD safety feature-equipped tank as described in the
"LP Tank" section of this manual.
• Always keep new and exchanged LP tanks in upright position
during use, transit or storage.
• Leak test new and exchanged LP tanks BEFORE
connecting to grill.
LP Tank Leak Test
For your safety
• Leak test must be repeated each time LP tank 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. Leaks are indicated by growing bubbles.
WARNING
1. LP tank must be properly secured onto grill. (Refer to
assembly section.)
2. Turn all control knobs to the OFF position.
3. Turn LP tank OFF by turning OPD hand wheel clockwise to a
full stop.
4. Remove the protective cap from LP tank 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.
If “growing” bubbles appear do not use or move the LP tank.
Contact an LP gas supplier or your fire department!
s Do not use household cleaning agents. Damage to gas
train components can result.
5. Hold regulator and insert nipple into LP
tank valve. Hand-tighten the coupling
nut, holding regulator in a straight line
with LP tank valve so as not to crossthread the connection.
Nipple has to be centered
into the LP tank valve.
463721108 • 463721308 • 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 tank 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 tank
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 tank.
3. Completely open LP tank valve by turning OPD 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 where bubbles are shown in
picture below:
s Never remove threaded
orifice at end of valve.
DANGER
• Do not insert any tool or foreign objects 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..
• If a leak is detected at any time, STOP and call the fire
department.
• If you cannot stop a gas leak, immediately close LP tank
valve and call LP gas supplier or your fire department!
WARNING
• 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.
5. If “growing” bubbles appear, there is a leak. Close LP tank
valve immediately and re-tighten connections. If leaks cannot
be stopped do not try to repair. Call for replacement parts.
Order new parts by giving the serial, model number, name and
part number of items needed (see parts list) to the Grill
Service Center at 1-800-241-7548.
6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.
6 • 463721108 • 463721308
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.
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 sideburner and side shelf is 10 lbs.
sThe grease tray must be inserted into grill and emptied after
each use. Do not remove grease tray 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.
sKeep ventilation openings in cylinder enclosure (grill cart) free
and clear of debris.
sDo 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.
sThe regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
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.
463721108 • 463721308 • 7
Ignitor Lighting
s Do not lean over grill while lighting.
1.
Turn OFF all 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
• 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.
• Do not leave grill unattended while preheating or
burning off food residue on high. If grill has not been
regularly cleaned, a grease fire can occur that may
damage the product. Follow instructions on General
Grill Cleaning and Cleaning The Burner Assembly to
prevent grease fires.
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
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.
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.
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.
8 • 463721108 • 463721308
Normal
Hose
Kinked
Hose
Turning Grill Off
• Turn all knobs to OFF position. Turn LP tank off by turning
OPD hand wheel clockwise to a full stop.
CAUTION
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.
SPIDER ALERT!
GAS COLLECTOR
BOX & IGNITOR
CONTROL PANEL
VALVE
AIR
SHUTTER
VENTURI
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.
LIFT OUT
BURNER ASSEMBLY
CLEAN OUT
VENTURI
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.
SPIDER WEBS
BURNER
REMOVE
BURNER
CLIPS
SPIDER WEBS
INSIDE VENTURI
• 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.
• 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.
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.
463721108 • 463721308 • 9
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