Char-Broil 463820208 Owner’s Manual

MODEL 463820208 ,, PRODUCT GUIDE

/_ 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 manual7 Wear
protective gloves if necessary.

463820208•80016427•12_04_07

if you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. ifodor continues, keep away from the
appliance and immediately call your gas

supplier or your fire department.

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 tank not connected for use shall not

er not connected for use shall not

be stored in the vicinity of this or any other

Call Grill Service Center for Help and Parts

• If you needassistance 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.

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, orin their
absence of local codes, with either the National Fuel Gas

Code,ANSI Z223.1/NFPA 54,Natural Gas and Propane
Installation Code, CSAB149.1, orPropane Storage and
Handling Code,B149.2, or the Standard forRecreational

Vehicles,ANSI A 119.2/NFPA1192,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 70or Canadian
Electrical Code, CSAC22.1. Keep any electrical cords and/or

fuel supply hoses away from any hot surfaces.

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

• This grill issafety certified for use in the United States and/or

Canadaonly. Do not modifyfor use in any other location.
Modification wilt resultin a safety hazard.

CALIFORNIA PROPOSITION65

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.

• Toorder non-warranty replacement parts or accessories
pleasevisit 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 assistyou.

iMPORTANT: Fill out the product record information below.

Model Number

Serial Number

Seeratinglabelongrillforserialnumber.

Date Purchased

CAUT'O.

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

Safety Symbols
The symbolsand boxes shown below explain what each heading

means. Read and follow all of the messages found throughout
the manual.

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

WARNING: Indicates an potentiallyhazardous situation
which, if not avoided,could result indeath or serious injury.

CAUTION

CAUTION: Indicates a potentially hazardoussituation or

unsafepracticewhich, ifnot avoided, may result inminor

or moderate injury.

2 • 463820208

For YourSafety...................................... 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 ....................................... 13-19

Troubleshooting.................................. 20-21

Limited Warranty .................................... 22

Registration Card ................................... 23

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.

463820208 • 3

• NEVERstore a spare LP tank under or near the
appliance or in an enclosed area.

• Never fill a tank beyond 80% full.

• An over filled or improperlystored tank is a

hazard due to possible gas release from the

safety relief valve.

• If you see, smell or hear gas escaping,

immediatelyget away from the LP tank/appliance

and call your fire department.

• If the above is not followed exactly, a fire causing
death or serious injury may occur.

LP tank

• The LP tank used with your grill must meet the following
requirements:

• Use LP s only with these required measurements: 12" (30.5cm)

(diameter) x 18" (45.7 cm) (tall) with 20lb. (9 kg.) capacity

maximum.

• LPtanks must beconstructed and marked in accordance with

specifications for LP tanks of the U.S. Department of
Transportation (DOT) orfor Canada, CAN/CSA-B339, tanks,

spheres and tubes for transportationof dangerous goods.
Transport Canada (TC). See LP tank collarfor marking.

• LPtank valve must have:

• Type 1 outlet compatiblewith
regulatoror grill.

• Safety relief valve.

• UL listed Overfill Protection
Device (OPD).This OPD safety OPDHandWheel

feature is identified by a uniquetriangular hand wheel. Use

only LP tanks equipped with this type of valve.

• LPtank must be arranged for vapor withdrawal and include
collar to protect LP tankvalve.Always keep LP tanks in upright

positionduring use, transit orstorage.

LP tank Removal, Transport and Storage

• Turn OFF all control knobs and LP tank valve. Turn coupling

nutcounterclockwise by handonly - do not use tools to

disconnect .Loosen tank screw beneath bottom shelf, then lift

LP tank up and out of cart. Placedust cap on tank valve outlet
whenever the tank is not in use. Only installthe type of dust
cap on the tank valve outletthat is provided with the tank

valve. Always use cap and strap supplied with valve. Other
types of caps or plugs may result in leakage of propane.

Failure to use dust cap as directed may result in serious

personal injuryand/or property damage.

• A disconnected LP tank in LPtank Valve
storage or being transported

must havea dust cap installed (as shown).
Do not store an LPtank in enclosed spaces

such as a carport, garage, porch, covered
patio or other building. Never leavean LP tank

inside a vehicle which may become overheated
by the sun.

• Do notstore an LPtank in an areawhere children play.

RetainerStrap

Dust
Cap

LP tank inupright position for vapor withdrawal

LP (Liquefied Petroleum Gas)

• LP gas is nontoxic, odorless andcolorless when produced. For

Your Safety, LPgas has been given an odor (similar to rotten
cabbage) so that it can besmelled.

• LP gas is highly flammable and may ignite unexpectedly when
mixed with air.

LP tank Filling

• Use only licensedand experienced dealers.

• LPdealer must purge new tank before filling.

• Dealer should NEVER fill LPtank more than 80% of LP tank
volume. Volume of propane in tank wilt vary by temperature.

• A frosty regulator indicates gas overfill. Immediately close LP
tank valve and call local LPgas dealer for assistance.

• Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.

• Toremove gas from LPtank, contact an LP dealer orcall a
local fire department for assistance. Check the telephone

directory under "Gas Companies" for nearest certified LP
dealers.

4 • 463820208

LP tank Exchange

Connecting Regulator to the LP tank

• Many retailers that sell grills offer you the option of replacing
your empty LPtank through an exchange service. Use only

those reputable exchange companies that inspect, precision fill,
test and certify their tanks. Exchange your tank only for an

OPB 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 mustbe repeated each time LP tank isexchanged 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 ignitionsources such as gas fired or electrical
appliances. Duringleak test, keep grillaway from open flames

or sparks.

• Use a clean paintbrushand a 50/50 mild soap and water
solution. Brush soapy solution onto areas indicated by arrows

in figure below.

A Do not use household cleaning agents. Damageto gas

train components can result.

1. LP tank must beproperly secured onto grill. (Referto
assembly section.)

2. Turnall control knobs to the OFF position.

3. Turn LPtank OFF by turning hand-wheel clockwise to a full
stop.

4. Remove the protective capfrom LP tank valve.Always use
cap andstrap supplied with valve.

OPD Hand Wheel

j Type1outlet with

threadon outside

Safety Relief Valve

/

Strapand Cap

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 useor move the LP

tank, Contact an LPgas supplier oryour fire department!

5. Hold regulator andinsert nipple into LP
tank valve. Hand-tightenthe coupling

nut, holding regulator ina straight line

with LP tankvalve so as not to cross-

thread the connection.

Continued on nextpage.

Nipplehasto becentered
intothe LP tankvalve.

463820208 • 5

Leak Testing Valves, Hose and Regulator

1. Turn all grill control knobs to OFF.

2. Be sure regulator istightly connected to LP tank.

3. Completely open LPtank 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.

Holdcoupling nut andregulator
asshown for properconnection

to LPtank valve.

6. Turnthe coupling nut clockwise and tighten to a full stop. The
regulatorwill seal onthe back-checkfeature 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 regulatorand

repeat steps 5 and 6. If you are still unable to completethe
connection, do not use this regulator!

4. Brush soapysolution onto areas circled below.

A Neverremovethreaded

orifice atend of valve.

Do not insertanytool or foreignobject intothe valve

outlet or safety relief valve.You may damagethe valve

and causea leak. Leaking propanemay result in
explosion,fire, severepersonal injury,or death.

Outdoorgas appliance is not intendedto be installed
in or on a boat.

Outdoorgas appliance is not intendedto be installed
in or on an RV.

, Never attemptto attach this grill to theself-contained

LPgas system of a campertrailer or motorhome.

, Do not usegrill until leak-tested.
, If a leak is detectedat any time, STOPand callthe fire

department.

, If you cannot stop a gas leak,immediately close

Lptankvalve and call LP gas supplieror your fire
department!

.

If "growing" bubblesappear, there is a leak. Close LP tank

valve immediately and retighten connections. If leaks cannot

be stopped do not try to repair. Call for replacement parts.
Order newparts by giving the serial, model number and name
and part numberof items needed(see parts list) to the Grill

Service Center at 1-800-241-7548.

.

Always close LP tankvalve after performingleak test by

turning handwheel clockwise.

6 • 463820208

For Safe Use of Your Grill and to Avoid Serious
Injury:

• Do not letchildrenoperate or play near grill.

• Keepgrill area clear and freefrom materials that burn.

• Do not blockholes insides or backof grill.

• Check burnerflames regularly.

• Use grill only inwell-ventilated space. NEVERuse in
enclosedspace suchas carport, garage, porch,

covered patio,or under anoverhead structureof any
kind.

Do not usecharcoal or ceramic briquetsin a gas grill.
(Unlessbriquets aresupplied with your grill.)

Usegrill at least 3 ft. from any wall or surface.
Maintain 10 ft. clearanceto objects that cancatch fire

or sources of ignitionsuch as pilot lightson water

heaters,live electrical appliances,etc..

Safety Tips
A Beforeopening LP tank valve, check the coupling nutfor

tightness.

A When grill is not in use, turn off all control knobs and LP tank

valve.

A Ifthe outdoor cooking gas appliance is not in use, the gas

must beturned off at the supply tank. Storage of an outdoor
cooking gas appliance indoors ispermissible only if the tank

isdisconnected and removed fromthe appliance.
A Nevermovegrill while in operation or still hot.
A Uselong-handled barbecue utensils andoven mitts to avoid

burnsand splatters.
A Maximumloadfor side shelves is 10Ibs.

A The grease cup must be inserted into grease clip and

emptied after each use. Do not remove grease cup until grill

has completelycooled.
A Clean grilloften, preferably after each cookout. If a bristle

brush is used to clean any of the grill cooking surfaces,

ensure no loose bristles remain oncooking surfaces priorto
grilling. It is not recommendedto clean cooking surfaces

while grill is hot.

A Ifyou noticegrease or other hot material dripping from grill

onto valve, hose or regulator, turn off gas supply at once.

Determinethe cause, correct it, then clean and inspect valve,

hoseand regulator before continuing. Performa leak test.
A The regulator may makea humming orwhistling noiseduring

operation. This will not affect safetyor use of grill.

A Onlyuse 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.
A Ifyou have a grill problem see the "Troubleshooting Section".
A Ifthe regulator frosts, turn off grill and LP tankvalve

immediately.This indicatesa problem with the tank and it

should notbe used on any product. Return to supplier!

• Apartment Dwellers:
Checkwith managementto learnthe requirements

and firecodes for using an LPgas grill in your
apartmentcomplex. If allowed, use outside onthe

ground floorwith a three (3)foot clearance fromwalls
or rails. Do not use onor under balconies.

• NEVERattempt 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

positionspecified in assembly instructions.

• Always close LPtank valve and remove coupling
nut before movingLP tank from specified

operationposition.

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. Personalinjury
may result. If a grease fire develops, turn knobs

and LP tank off.
Do not leave grill unattendedwhile 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.

463820208 • 7

Ignitor Lighting
A Do notlean over grill while lighting.

1. TurnOFF gas burner control valves.

2. Turn ON gas source or tank.

3. Open lid during lighting.

4. Toignite,turn ignition left knob to PRE-HEAT_I:,Go to step 3.

5. Push IGNITORbutton rapidly.

6. If ignition doe NOT occur in 5 seconds,turn the burner
controls OFF,wait 5 minutes and repeat the lighting
procedure.

7. Toignite right burner, turn right knobto PRE-HEAT.

CAUTION

If ignitiondoes NOT occur in 5seconds, turn the
burner controls OFF,wait 5 minutes and repeat the

lighting procedure.If the burner does not ignitewith
the valve open, gas will continue to flow out of the

burner and could accidently ignite with risk of injury.

Match-Lighting

,& Do not lean over grill while lighting.

1. Open lid during lighting. Turn ongas at LP tank.

2. Place lit match into match holder,then into side of grill bottom
(as shown below).

3. Push inand turn IGNITION BURNERknob toJt: HI. Be sure
burner lights andstays lit.

4. Toignite right burner, turn right knobto HI.

Burner Flame Check

• Remove cooking grates and flametamers. Light burners, rotate
knobsfrom HI to LO. Youshould see a smaller flame in LO

position than seen on HI. Always check flame prior to each use.

If only low flame is seen referto "Sudden drop or low flame" in

the TroubleshootingSection.

Turning Grill Off

• Turn all knobs to OFF position. Turn LP tank off by turning
hand-wheelclockwise to a full stop.

Ignitor Check

• Turn gas off at LP tank. Press ignitor buttonrapidly. "Click"

should be heard and spark seen each time between collector

boxor burner and electrode. See "Troubleshooting" if no click

or spark.

Valve Check

• important: Make sure gas is off at LPtank before checking

valves. Knobslock in OFF position. Tocheck valves,first

pushin knobs and release,knobs should spring back. If knobs

do notspring back, replace valveassembly before using grill.
Turn knobsto LO position then turn back to OFF position.
Valves should turn smoothly.

Hose Check

• Before each use, check to see if hoses are cut or worn.

Replace damaged hoses before usinggrill. Use only

valve/hose/regulator specified by manufacturer.

General Grill Cleaning

• Do not mistake brown or black accumulation of grease and

smoke for paint. Interiorsof gas grills are not painted at the
factory (and should never be painted). Apply a strong solution
of detergent and water or usea grill cleanerwith scrub brush
on insides of grill lid and bottom. Rinse and allow to completely
air dry. Donot apply a caustic grill/oven cleaner to painted

surfaces.

• Plastic parts: Wash with warm soapy water and wipe dry.

A Donot 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
residuecan bewiped away with baking soda/water solution or

specially formulated cleaner. Use nonabrasive scouring powder
for stubborn stains.

• Painted surfaces: Wash with milddetergent or nonabrasive

cleaner andwarm soapy water. Wipe dry with a soft
nonabrasive cloth.

• Cooking surfaces: If a bristle brush is used to clean any of

the grill cooking surfaces, ensure no loose bristles remain on
cooking surfaces priorto grilling. It is not recommendedto

clean cookingsurfaces while grill is hot.

8 • 463820208