Char-Broil 463821908 User Manual

Page 1

MODEL 463821908 • PRODUCT GUIDE

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.

463821908 • 80016556 • 01-10-08

Page 2

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

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.

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

• 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.

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 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.

IMPORTANT: Fill out the product record information below.

Model Number

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.

DANGER

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

Serial Number

See rating label on grill for serial number.

Date Purchased

CAUTION

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

2 • 463821908

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.

Page 3

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-22

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-25

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

To insure your satisfaction

and for follow-up service,

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.

463821908 • 3

Page 4

USE AND CARE

DANGER

• NEVER store 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 improperly stored tank is a hazard due to possible gas release from the safety relief valve.

• If you see, smell or hear gas escaping, immediately get 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 20 lb. (9 kg.) capacity maximum.

• LP tanks must be constructed and marked in accordance with specifications for LP tanks of the U.S. Department of Transportation (DOT) or for Canada, CAN/CSA-B339, tanks, 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. Always keep LP tanks in upright position during use, transit or storage.

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 .Loosen tank screw beneath bottom shelf, then lift LP tank up and out of cart. Place dust cap on tank valve outlet whenever the tank is not in use. Only install the type of dust cap on the tank valve outlet that 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 injury and/or property damage.

• A disconnected LP tank in

storage or being transported must have a dust 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 tank Valve

Dust Cap

Retainer Strap

LP tank 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 tank Filling

• Use only licensed and experienced dealers.

• LP dealer must purge new 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.

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Page 5

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 tanks. 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. 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 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 hand-wheel clockwise to a full stop.

4. Remove the protective cap from LP tank valve. Always use

cap and strap supplied with valve.

Strap and Cap

OPD Hand Wheel

Type 1 outlet with thread on outside

Safety Relief Valve

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 tank. Contact an LP gas supplier or your fire department!

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.

Continued on next page.

Nipple has to be centered into the LP tank valve.

463821908 • 5

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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 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.

s Never remove threaded orifice at end of valve.

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 Lptank valve and call LP gas supplier or your fire department!

5. If “growing” bubbles appear, 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 new parts by giving the serial, model number and 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.

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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 sides 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 tank valve, check the coupling nut for

tightness.

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

valve.

sIf the outdoor cooking gas appliance is not in use, the gas

must be turned off at the supply tank. Storage of an outdoor cooking gas appliance indoors is permissible only if the tank 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 tank valve

immediately. This indicates a problem with the tank 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 tank 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.

463821908 • 7

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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 ignition left knob to PRE-HEAT ,Go to step 3 .

5. Push IGNITOR button rapidly.

6. If ignition doe NOT occur in 5 seconds, turn the burner

controls OFF, wait 5 minutes and repeat the lighting procedure.

7. To ignite right burner, turn right knob to PRE-HEAT. If ignitor does not work, follow match lighting instructions.

CAUTION

If ignition does NOT occur in 5 seconds, turn the burner controls OFF, wait 5 minutes and repeat the lighting procedure. If the burner does not ignite with the valve open, gas will continue to flow out of the burner and could accidently ignite with risk of injury.

Match-Lighting

s Do not lean over grill while lighting.

1. Open lid during lighting. Turn on gas at LP tank.

2. Place lit match into match holder, then into side of grill bottom

(as shown below).

3. Push in and turn IGNITION BURNER knob to HI. Be sure burner lights and stays lit.

4. To ignite right burner, turn right knob to HI.

Burner Flame Check

• Remove cooking grates and flame tamers. Light burners, rotate knobs from HI to LO. You should see a smaller flame in LO position than seen on HI. Always check flame prior to each use. If only low flame is seen refer to "Sudden drop or low flame" in the Troubleshooting Section.

Turning Grill Off

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

OFF

Ignitor Check

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

should be heard and spark seen each time between collector box or burner and electrode. See "Troubleshooting" if no click or spark.

Valve Check

• Important: Make sure gas is off at LP tank before checking valves. Knobs lock in 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 position. Valves should turn smoothly.

OFF

Hose Check

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

Replace damaged hoses before using grill. Use only valve/hose/regulator specified by manufacturer.

General Grill Cleaning

• Do not mistake brown or black accumulation of grease and smoke for paint. Interiors of gas grills are not painted at the factory (and should never be painted). 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.

• 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 surfaces: Because of glass-like composition, most residue can be wiped away with baking soda/water solution or specially formulated cleaner. Use nonabrasive 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.

• 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.

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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

INSIDE VENTURI

SPIDER WEBS

BURNER

REMOVE BURNER

CLIPS

SPIDER WEBS

INSIDE VENTURI

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 tank.

2. vaporiser b

Remove cooking grate and ar.

Under grill remove grease cup, disconnect ignitor wire and clips from burner. To remove clips pull down on large end of clip attached to the valve, turn away from valve, rotate upward and remove small end of clip from burner tube (A).

Inside grill remove burner assembly (B), clean ceramic portion of electrode with rubbing alcohol and a swab.

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.

If grill is to be stored, coat burner lightly with cooking oil. Wrap in protective cover to keep insects out.

If not storing grill after cleaning, replace burner into grill bottom.

To reattach clips hold large curved end away from burner tube, insert small curved end into hole under burner tubes, turn clip towards valve, snap into place.

VERY IMPORTANT: Burner tubes must reengage valve

openings. See illustration (A).

9. electrode

Reattach ignitor wire to .

10. vaporiser

Reposition bar and cooking grate. Reattach clean grease cup

11.

Before cooking again on grill, perform a “Leak Test” and “Burner Flame Check”.

to grease clip.

Burner Tube

Valve

Storing Your Grill

• Clean cooking grates.

• Store in dry location.

• Cover grill if stored outdoors. Choose from a variety of grill covers offered by manufacturer.

• When LP tank is connected to grill, store outdoors in a wellventilated space and out of reach of children.

• If the outdoor cooking gas appliance is not in use, the gas must be turned off at the supply tank. Storage of an outdoor cooking gas appliance indoors is permissible only if the tank is disconnected and removed from the appliance.

• Store grill indoors ONLY if LP tank is turned off and disconnected, removed from grill and stored outdoors.

• When removing grill from storage, follow “Cleaning the Burner Assembly” instructions before starting grill.

Correct burner-to-valve engagement

463821908 • 9

Page 10

Food Safety

Food safety is a very important part of enjoying the outdoor cooking experience. To keep food safe from harmful bacteria, follow these four basic steps:

Clean: Wash hands, utensils, and surfaces with hot soapy water

before and after handling raw meat and poultry.

Separate: Separate raw meats and poultry from ready-to-eat

foods to avoid cross contamination. Use a clean platter and utensils when removing cooked foods.

Cook: Cook meat and poultry thoroughly to kill bacteria. Use a

thermometer to ensure proper internal food temperatures.

Chill: Refrigerate prepared foods and leftovers promptly.

For more information call: USDA Meat and Poultry Hotline at 1-800-535-4555 In Washington, DC (202) 720-3333, 10:00 am4:00 pm EST.

How To Tell If Meat Is Grilled Thoroughly

• Meat and poultry cooked on a grill often browns very fast on the

outside. Use a meat thermometer to be sure food has reached a safe internal temperature, and cut into food to check for visual signs of doneness.

• Whole poultry should reach 180° F; breasts, 170° F. Juices should run clear and flesh should not be pink.

• Hamburgers made of any ground meat or poultry should reach 160° F, and be brown in the middle with no pink juices. Beef, veal and lamb steaks, roasts and chops can be cooked to 145° F. All cuts of pork should reach 160° F.

• NEVER partially grill meat or poultry and finish cooking later. Cook food completely to destroy harmful bacteria.

• When reheating takeout foods or fully cooked meats like hot dogs, grill to 165° F, or until steaming hot.

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Page 11

PARTS LIST – Model No. 463821908

Key Qty Description . . . . . . . . . . . . . . . . . . . Part #

A 1 Firebox. . . . . . . . . . . . . . . . . . . . . 80011600

B 1 Valve/Hose/Regulator . . . . . . . . . 80016425

C 1 Control Panel . . . . . . . . . . . . . . . . 80016558

D 2 Control Knobs . . . . . . . . . . . . . . . 80008245

E 1 Ignitor. . . . . . . . . . . . . . . . . . . . . . 5156113

F 2 Axle F/Wheel . . . . . . . . . . . . . . . . 80011619

G 1 Left Cart Assy w/match holder. . . 80011604

H 1 Burner Assembly . . . . . . . . . . . . . 80011601

I 2 Wheels. . . . . . . . . . . . . . . . . . . . . 80008000

J 1 Right Cart Leg . . . . . . . . . . . . . . . 80011605

K 2 Leg Extenders . . . . . . . . . . . . . . . 80008291

L 1 Bottom Shelf . . . . . . . . . . . . . . . . 80011606

M 1 Back Support Brace. . . . . . . . . . . 80011607

N 1 Tank Retainer. . . . . . . . . . . . . . . . 80008294

O 1 Front Panel . . . . . . . . . . . . . . . . . 80011608

P 1 Side Shelf . . . . . . . . . . . . . . . . . . 80011609

Q 1 Lid . . . . . . . . . . . . . . . . . . . . . . . . 80011610

R 1 Logo Plate Assembly . . . . . . . . . . 80011611

S 1 Handle Assembly. . . . . . . . . . . . . 80011612

T 1 Sideburner Frame . . . . . . . . . . . . 80011613

U 1 Sideburner Pan . . . . . . . . . . . . . . 80011614

V 1 Sideburner Grate . . . . . . . . . . . . . 80010163

W 1 Tool Holder. . . . . . . . . . . . . . . . . . 80011615

X 1 Sideburner Valve Cup . . . . . . . . . 80011616

Y 1 Sideburner . . . . . . . . . . . . . . . . . . 80016559

Z 1 Sideburner Knob . . . . . . . . . . . . . 80010161

Key Qty Description . . . . . . . . . . . . . . . . . . . Part #

AA 1 Heat Tent . . . . . . . . . . . . . . . . . . . 80008273

BB 1 Cooking Grate . . . . . . . . . . . . . . . 80008274

CC 1 Swing Away . . . . . . . . . . . . . . . . . 80008275

DD 2 Lower Hinge. . . . . . . . . . . . . . . . . 80011618

EE 2 Upper Hinge. . . . . . . . . . . . . . . . . 80011617

FF 1 Grease Cup . . . . . . . . . . . . . . . . . 80000270

GG 1 Clip, Grease Cup. . . . . . . . . . . . . 80000271

HH 1 Heat Shield F/Tank . . . . . . . . . . . 80016679

II 1 Heat Shield F/Firebox . . . . . . . . . 80016680

1 Product Manual, English . . . . . . . 80016556

1 Hardware Pack . . . . . . . . . . . . . . 80009105

1 Venturi Clip 2 Axle Bolt 6 Wing Nut, Plastic 7 #10-24x2" Carriage Bolt 4 Hitch Pin 22 #10-24 Flange Nut 28 Silicone Washer 4 #10-24x1-1/4" Machine Screw 3 #10-24 Wing Nut, Metal 5 #10-24 T-Wing Screw 6 #10-24x2" Machine Screw 16 #10-24x1/2" Machine Screw 2 Insulation Washer 2 Hinge Pin

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.

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PARTS DIAGRAM – Model No. 463821908

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Page 13

ASSEMBLY – Model No. 463821908

Axle Bolt

A Attach right leg assembly to bottom shelf with (2) #10-24x2" carriage bolts and #10-24 Plastic wing nuts. B Push Leg Extenders into the bottom of the right legs. C Place left leg assembly into bottom shelf. Insert axle bolts into wheels, legs and bottom shelf. Secure with hitch pins.

Left Leg Assembly

1” Hitch Pin

Qty.2

Right Leg Assembly

#10-24 X 2” Carriage Bolt

Qty.2

“Cone” side of wheel against leg

Qty.2

Wheel

Bottom

Shelf

#10-24 Plastic Wing Nuts

Attach back support brace to legs with (4) #10-24x2" carriage bolts and #10-24 Plastic wing nuts.

#10-24 X 2” Carriage Bolt

Qty.4

Qty.2

Leg Extender

Back Support Brace

#10-24 Plastic Wing Nuts

Qty.4

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#10-24 X 2”

Machine Screw

A Place bottom of front panel into three slots in the bottom shelf. B Attach front panel to legs with four #10-24x2" machine screws and #10-24 flange nuts.

Qty.4

#10-24 Flange Nut

Qty.4

A Place valve/hose/regulator onto control panel. Attach with machine screws. NOTE: Make sure the two valve

stems are centered in their clearance holes; otherwise, this can cause main burner level problems. B Insert ignitor body into ignitor hole on control panel, then tighten it with sheetmetal nut. NOTE: if your grill come with Snap-in ignitor, please see Option.

#10-24 x ½”

Machine Screw

Qty.2

Ignitor

#10-24 x ½”

Option: Snap the

ignitor into the control panel.

Back of Cart

Snap-in

Ignitor

14 • 463821908

Sheetmetal Nut

Valve/Hose/Regulator

Page 15

Attach control panel to firebox using #10-24 x ½” machine screws, silicon washers and #10-24 flange nuts.

#10-24 x ½”

Machine Screw

Qty. 4

Silicon Washer

Qty. 4

#10-24

Flange Nut

Qty. 4

Firebox

A Place firebox onto cart, make sure the regulator hose hangs inside cart and control panel overlaps front panel.Attach to cart with

#10-24x1-1/4"

Machine Screw

#10-24x1-1/4" machine screws, Silicon washers and #10-24 flange nuts. B Place burners assembly into firebox, making sure valves are inside the burner tubes. Attach to firebox with machine screws and silicon washers. C Attach wire of main burner to ignitor.

Qty: 4

#10-24 x ½”

Machine Screws

Qty. 2

Silicon Washer

Firebox

Qty: 6

Control Panel

#10-24 x ½”

Burner Assembly

#10-24

Flange Nuts

Qty. 4

Correct burner-to-valve engagement

Front Panel

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A Attach tool holder to front leg using two #10-24x2" machine screws and #10-24 flange nuts. Place sideburner pan into frame and

attach with a #10-24x2" carriage bolt and #10-24 metal wing nut in back and a T-wing screw in front.

B Attach sideburner valve cup. Place sideburner into hole. Make sure side burner valve is inside sideburner tube. Fasten sideburner

with a wing nut. Hook burner clip to sideburner tube and around manifold. Attach sideburner ignitor wire to ignitor.

C Place sideburner knob and grate.

#10-24x2" Carriage Bolt

Sideburner Pan

Metal

Wing Nut

Tool

Holder

Flange Nut

Sideburner Frame

T-Wing

Screw

#10-24x2"

Machine Screw

#10-24

Flange Nut

Qty: 2

Sideburner Clip

Qty: 1

Sideburner

#10-24

Metal Wing Nut

Qty. 1

#10-24

T-Wing Screw

Qty: 1

Machine Screw

Sideburner Grate

16 • 463821908

#10-24 X 2”

Qty. 2

#10-24x2”

Carriage Bolts

Qty: 1

Sideburner

Knob

Sideburner ignitor wire

Sideburner

Valve

Cup

Correctly assembled valve in sideburner tube

Sideburner

Clip

Page 17

Attach side shelf with #10-24 T-wing screw.

#10-24

T-Wing Screw

Qty: 4

Lower Hinge

Attach lower lid hinges to back of firebox using #10-24x1/2" machines screws, silicon washers and #10-24 flange nuts per hinge. The center flat portion of the hinge should be at the bottom (see inset).

#10-24

Flange Nuts

Qty:4

Silicon Washer

Qty:8

Center flat portion

of hinge on bottom

#10-24 X ½”

Machine Screw

Qty:4

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#10-24 Wing Nut

Machine Screw

Silicon Washer

Attach handle to front of lid with silicon washers , insulation washers and #10-24 wing nuts. Upper lid hinges attach to back with #10-24x1/2" machine screws, fiber washers and #10-24 flange nuts. Do not tighten the screws.

Qty:2

#10-24X1/2”

Qty:4

Qty:10

#10-24

Flange Nuts

Qty:4

Place lid assembly onto firebox, aligning hinges. Hinges on lid fit inside hinges on firebox. Secure with hinge pins and hitch pins. Tighten upper lid hinges .screws

Insulation Washer

Qty:2

1” Hitch Pin

Qty. 2

Hinge Pin

Qty. 2

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Place heat tent onto V-shaped bar rests inside firebox. Place cooking grate onto firebox.

Cooking Grate

Heat Tent

A Insert ends of Swing Away pivot wire into holes in sides of grill lid. Insert ends of Swing Away leg wire into holes in sides of

firebox. NOTE: Pivot and leg wires, running side-to-side, should be under wires running front-to-back. If pivot and leg wires are on top Swing Away is installed upside-down.

B Push control knobs onto valves.

Pivot Wire

Swing Away

Leg

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Insert tank wire into holes in bottom shelf of the cart.

Tank Wire

Hang grease cup clip from bottom of firebox and place grease cup into grease clip. bottom of tank into bottom shelf. Rotate tank wire up to secure tank. LP tank IS SOLD SEPARATELY. Fill and leak check the tank before attaching to grill and regulator (see Use & Care Section). See Use & Care section of this manual to perform the "Burner Flame Check" and for important safety instructions

before using.

Grease Cup Clip

Grease Cup

Tank collar opening must face to left of grill. Set

CAUTION

Failure to install grease cup clip and cup will cause hot grease to drip from bottom of grill with risk of fire or property damage.

Always keep LP Tanks in

upright position during use,

transport, and storage

20 • 463821908

CAUTION

tank valve must face to front of cart once tank is attached. Failure to install tank correctly may allow gas hose to be damaged in operation, resulting in the risk of fire.

Page 21

EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

Emergencies

Gas leaking from cracked/cut/burned hose.

Gas leaking from LP tank.

Gas leaking from LP tank valve.

Gas leaking between LP tank and regulator connection.

Fire coming through control panel.

Grease fire or continuous excessive flames above cooking surface.

Troubleshooting

Problem

Possible Cause

• Damaged hose.

• Mechanical failure due to rusting or mishandling.

• Failure of tank valve from mishandling or mechanical failure.

• Improper installation, connection not tight, failure of rubber seal.

• Fire in burner tube section of burner due to blockage.

• Too much grease buildup in burner area.

Possible Cause

Prevention/Solution

• Turn off gas at LP tank or at source on natural gas systems. If anything but burned, replace valve/hose/regulator. If burned, discontinue use of product until a plumber has investigated cause and corrections are made.

• Replace LP tank.

• Turn off LP tank valve. Return LP tank to gas supplier.

• Turn off LP tank valve. Remove regulator from tank and visually inspect rubber seal for damage. See LP tank Leak Test and Connecting Regulator to the LP tank.

• Turn off control knobs and LP tank valve. Leave lid open to allow flames to die down. After fire is out and grill is cold, remove burner and inspect for spider nests or rust. See Natural Hazard and Cleaning the Burner Assembly pages.

• Turn off control knobs and LP tank valve. Leave lid open to allow flames to die down. After cooling, clean food particles and excess grease from inside firebox area, grease cup, and other surfaces.

Prevention/Solution

Burner(s) will not light using ignitor.

Continued on next page.

GAS ISSUES:

• Trying to light wrong burner.

• Burner not engaged with control valve.

• Obstruction in burner.

• No gas flow.

• Vapor lock at coupling nut to LP tank.

• Coupling nut and LP tank valve not fully connected.

ELECTRICAL ISSUES:

• Electrode cracked or broken; “sparks at crack.”

• Electrode tip not in proper position.

• Wire and/or electrode covered with cooking residue.

• See instructions on control panel and in Use and Care section.

• Make sure valves are positioned inside of burner tubes.

• Ensure burner tubes are not obstructed with spider webs or other matter. See cleaning section of Use and Care.

• Make sure LP tank is not empty. If LP tank is not empty, refer to “Sudden drop in gas flow.”

• Turn off knobs and disconnect coupling nut from LP tank. Reconnect and retry.

• Turn the coupling nut approximately one-half to three-quarters additional turn until solid stop. Tighten by hand only - do not use tools.

• Replace electrode(s).

Main Burners:

• Tip of electrode should be pointing toward gas port opening on burner. The distance should be 1/8” to 1/4”. Adjust if necessary.

Sideburner (if featured):

• Tip of electrode should be pointing toward gas port opening on burner. the distance should be 1/8” to 3/16”. Adjust if necessary.

• Clean wire and/or electrode with rubbing alcohol and clean swab.

• Wires are loose or disconnected.

• Wires are shorting (sparking) between ignitor and electrode.

• Reconnect wires or replace electrode/wire assembly.

• Replace ignitor wire/electrode assembly.

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Troubleshooting (continued)

Problem

Burner(s) will not light using ignitor.

Burner(s) will not match light.

Low flame, drop in gas flow.

Possible Cause

PIEZO PUSH-BUTTON AND ROTARY:

• Push-button sticks at bottom.

• Rotary knob rotates without clicking.

• Sparking between ignitor and electrode.

• See “GAS ISSUES:” on previous page.

• Match will not reach.

• Improper method of match-lighting.

• Out of gas.

• Excess flow valve tripped.

• Vapor lock at coupling nut/LP tank connection.

Prevention/Solution

• Replace ignitor.

• Replace knob.

• Inspect wire insulation and proper connection. Replace wires if insulation is broken.

• Use long-stem match (fireplace match).

• See “Match-Lighting” section of Use and Care.

• Check for gas in LP tank.

• Turn off control and tank knobs, wait 30 seconds, turn tank knob on slowly, light grill. If flames are still low, turn off control and tank knobs and disconnect regulator. Reconnect regulator, turn tank knob on slowly, light grill.

• Turn off control and tank knobs and disconnect regulator. Reconnect regulator, turn on tank knob slowly, light grill.

Flames blow out.

Flare-up.

Persistent grease fire.

Flashback... (fire in burner tube(s)).

Unable to fill LP tank.

• High or gusting winds.

• Low on LP gas.

• Excess flow valve tripped.

• Grease buildup.

• Excessive fat in meat.

• Excessive cooking temperature.

• Grease trapped by food buildup around burner system.

• Burner and/or burner tubes are blocked.

• Some dealers have older fill nozzles with worn threads.

• Turn front of grill to face wind or increase flame height.

• Refill LP tank.

• Refer to “Sudden drop in gas flow” above.

• Clean burners and inside of grill/firebox.

• Trim fat from meat before grilling.

• Adjust (lower) temperature accordingly.

• Turn knobs to OFF. Turn gas off at LP tank. Leave lid in position and let fire burn out. After grill cools, remove and clean all parts.

• Turn knobs to OFF. Clean burner and/or burner tubes. See burner cleaning section of Use and Care.

• The worn nozzles don’t have enough “bite” to engage the valve. Try a second LP dealer.

22 • 463821908

Page 23

LIMITED WARRANTY

Manufacturer warrants to the original consumer-purchaser only that this product shall be free from defects in workmanship and materials after

correct assembly and under normal and reasonable home use for the periods indicated below beginning on the date of purchase.

The manufacturer reserves the right to require that defective parts be returned, postage and or freight pre-paid, by the consumer, for review and

examination.

All Parts - 1 year

Upon consumer supplying proof of purchase as provided herein, Manufacturer will repair or replace the parts listed below which are proven defective during the applicable warranty period. Parts required to complete such repair or replacement shall be free of charge to you except for shipping costs. The original consumer-purchaser will be responsible for all shipping charges of parts replaced under the terms of this

limited warranty.

This limited warranty is applicable in the United States and Canada only, is only available to the original owner of the product and is not transferable. Manufacturer requires reasonable proof of your date of purchase. Therefore, you should retain your sales slip or invoice and register your new product immediately. Defective or missing parts subject to this limited warranty will not be replaced without registration or proof of purchase. Register online at http://www.charbroil.com or complete and return via mail the Product Registration Card located on the last page of the Use & Care manual included with this product and retain your sales receipt for proof of purchase.

This limited warranty applies to the functionality of the product ONLY and does not cover cosmetic issues such as scratches, dents, corrosions or discoloring by heat, abrasive and chemical cleaners or any tools used in the assembly or installation of the appliance, surface rust, or the discoloration of stainless steel surfaces.

This limited warranty will not reimburse you for the cost of any inconvenience, food, personal injury or property damage.

If an original replacement part is not available, a comparable replacement part will be sent. You will be responsible for all shipping charges of parts replaced under the terms of this limited warranty.

ITEMS MANUFACTURER WILL NOT PAY FOR:

1. Service calls to your home.

2. Repairs when your product is used for other than normal, single-family household or residential use.

3. Damage resulting from accident, alteration, misuse, abuse, fire, flood, acts of God, improper installation, installation not in accordance with

electrical or plumbing codes, or use of products not approved by the manufacturer.

4. Any food loss due to product failures.

5. Replacement parts or repair labor costs for units operated outside the United States or Canada.

6. Pickup and delivery of your product.

7. Repairs to parts or systems resulting from unauthorized modifications made to the product.

8. The removal and/or reinstallation of your product.

9. Shipping cost, standard or expedited, for warranty and replacement parts.

DISCLAIMER OF IMPLIED WARRANTIES; LIMITATION OF REMEDIES

Repair or replacement of defect parts is your exclusive remedy under the terms of this limited warranty. Manufacturer will not be responsible for any consequential or incidental damages arising from the breach of either this limited warranty or any applicable warranty, or for failure or damage resulting from acts of God, improper care and maintenance, grease fire, accident, alteration, replacement of parts by anyone other than Manufacturer, misuse, transportation, commercial use, abuse, hostile environments (inclement weather, acts of nature, animal tampering), improper installation or installation not in accordance with local codes or printed manufacturer instructions. THIS LIMITED WARRANTY IS THE SOLE EXPRESS WARRANTY GIVEN BY THE MANUFACTURER. NO PRODUCT PERFORMANCE SPECIFICATION OR DESCRIPTION WHEREVER APPEARING IS WARRANTED BY MANUFACTURER EXCEPT TO THE EXTENT SET FORTH IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTY PROTECTION ARISING UNDER THE LAWS OF ANY STATE, INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, IS HEREBY LIMITED IN DURATION TO THE DURATION OF THIS LIMITED WARRANTY.

Neither dealers nor the retail establishment selling this product has any authority to make any additional 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 documented purchase price of the product paid by the original consumer.

This warranty only applies to units purchased from an authorized retailer and or re-seller.

NOTE: Some states do not allow an exclusion or limitation of incidental or consequential damages, so some of the above limitations or exclusions may not apply to you. This limited warranty gives you specific legal rights as set for herein. You may also have other rights which vary from state to state. In the state of California only, if refinishing or replacement of the product is not commercially practicable, the retailer selling this product or the Manufacturer will refund the purchase price paid for the product, less the amount directly attributable to use by the original consumerpurchaser prior to discovery of the nonconformity. In addition, in the state of California only, you may take the product to the retail establishment selling this product in order to obtain performance under this limited warranty.

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

Char-Broil Consumer Relations

P. O. Box 1240

Columbus, GA 31902-1240

Consumer returns will not be accepted unless a valid Return Authorization is first acquired by calling 1-800-241-7548 and then clearly marked on the outside of the package and the package is shipped freight/postage pre-paid to the address above.

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Please register your grill online at:

WWW.GRILLREGISTRATION.COM

(If you register online, you do not need to send in this registration card.)

/ Envíelo a:

La parrilla estaba ensamblada

Chimenea

463821908 • 27

Page 28

STOP

Should you encounter a problem with our product

CALL US FIRST

Do not return this product to the store.

WE CAN HELP

GRILL SERVICE CENTER

1-800-241-7548

HOURS 8AM-6PM EST Mon-Fri

Please ensure your warranty registration is complete.

Grilling Safety Checklist

Read and understand owners manual. Never overfill LP tank. Overfilled tanks may cause freeze-up of

regulator. Check tubes for spider webs. Ensure valves are correctly installed in

burner tubes. Always ensure control knobs are in OFF position and regulator is

attached to tank BEFORE opening tank valve to avoid low flames. Perform leak test regularly.

Thank You for Your Purchase!

Char-Broil, LLC Printed in China • Columbus, GA 31902 •