Char-Broil 465640212 Product Manual

Product Guide
Stainless Steel
Tabletop Grill
Model 465640212

For support and to register your grill,
please visit us at www.charbroil.com

If you have questions or need
assistance during assembly, please
call 1-800-241-7548.

IMPORTANT: Fill out the product record information below.

Serial Number

See rating label on grill for serial number.

THIS GRILL IS FOR OUTDOOR USE ONLY.

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.

Failure to follow these instructions could result in
fire or explosion which could cause property
damage, personal injury or death.

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.

Date Purchased

WARNING

This manual contains important information necessary
for the proper assembly and safe use of the appliance.

Read and follow all warnings and instructions before
assembling and using the appliance.

Follow all warnings and instructions when using the
appliance.

Keep this manual for future reference

CAUTION

Some parts may contain sharp edges — especially as
noted in the manual! Wear protective gloves if necessary.

INSTALLER/ASSEMBLER: Leave these instructions with
consumer.
CONSUMER: Keep this manual for future reference.

© 2012 Char-Broil, LLC • Columbus, GA 31902 • Printed in China • Assembly Instructions © 2012

42804977 • 07-13-12

TABLE OF CONTENTS

Product Record Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DANGER

Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Food Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14

Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Safety Symbols

The symbols and boxes shown below explain what each heading
means. Read and follow all of the messages found throughout
the manual.

1. Never operate this appliance unattended.

2. Never operate this appliance within 10ft (3m) of
any structure, combustible material or other gas
cylinder.

3. Never operate this appliance within 25 ft (7.5 m)
of any flammable liquid.

4. If a fire should occur, keep away from the
appliance and immediately call your fire
department. Do not attempt to extinguish an oil

or grease fire with water.

Failure to follow these instructions could result in
fire, explosion or burn hazard, which could cause
property damage, personal injury or death.

CAUTION

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

WARNING

WARNING: Indicates an potentially hazardous situation
which, if not avoided, could result in death or serious injury.

DANGER

DANGER: Indicates an imminently hazardous situation
which, if not avoided, will 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.

CAUTION

• For residential use only. Not intended for commercial use.

• Do not leave appliance unattended. Keep children and
pets away from appliance at all times.

THIS GRILL IS FOR OUTDOOR USE ONLY.

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.

WARNING

Do not attempt to repair or alter the regulator/valve
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.

2

Installation Safety Precautions

• Use grill, as purchased, only with LP (propane) gas and the

regulator/valve assembly supplied.

• 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. Storage and handling of liquefied

petroleum gasses must conform to LP Gas Code

ANSI /NFPA 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. 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.

• Do not leave appliance unattended. Keep children and
pets away from appliance at all times.

USE AND CARE

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 (i.e.

•

gasoline, propane, or any other flammable liquid or gas).

•

Do not block holes in bottom or back of grill.
Check burner flames regularly.

•

• Never use regulator from this grill with any other LP
appliance.

• When cooking, the appliance must be on a level surface in
an area clear of combustible material.

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.

•

o

o

Safety Tips

 The use of alcohol, prescription or nonprescription drugs

may impair the consumer’s ability to properly assemble or
safely operate the appliance.

 When grill is not in use, disconnect 1 lb. cylinder.
 Never move grill while in operation or still hot. Allow the

appliance to cool before moving or storing.

 The regulator may make a humming or whistling noise

during operation. This will not affect safety or use of grill.

 If you have a grill problem see the Troubleshooting Section.
 Light burners. Check to make sure they are lit, close the lid

and warm up grill on high for 10 minutes. Curing of paint
and parts will produce an odor only on first lighting.

 Grill is not intended for and should never be used as a

heater.

 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.
 Use long-handled barbecue utensils and oven mitts to avoid

burns and splatters.

 If 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!

• This appliance is not intended for and should never be used
as a heater.

• 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..

A

3 ft. (.6m) minimum

10 ft. recommended

• 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 cylinder out of correct
position specified in assembly instructions

3

LP (Liquefied Petroleum 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.

Propane Cylinder Use (1 lb. Disposable)

Use only cylinder marked “Propane Fuel”.

•

•

Cylinder must be constructed and marked in accordance with
the specifications for LP-gas cylinders of the U.S. Department
of Transportation (DOT) or the National Standard of Canada,
CAN/CSA-B339, Cylinders, Spheres and Tubes for the
Transportation of Dangerous Goods.

•

Save cylinder cap and reinstall when not in use.

•

Cylinder supply system must be arranged for vapor
withdrawal. Gas cylinder must be upright in use.

Propane Gas Cylinders

- Your grill is designed to operate with one 16.4 oz. disposable
cylinder (Dot 39 Cylinder) that is 7 3/8” high (not included).

Do not attempt to refill any 16.4 oz. disposable fuel
cylinders.

- The cylinder must be installed, transported and stored in an
upright position and should not be dropped or handled
roughly.

- For outdoor use only, If stored indoors, Detach and leave
cylinder outdoors.

- When the propane gas cylinder is not disconnected from the

appliance, the appliance and cylinder must be stored
outdoors in a well-ventilated space.

- The cylinder should never be transported or stored where

temperature can reach 125 F (51 C).

- Cylinders must be stored outdoors out of the reach of

children.

Propane Cylinder Installation/Removal

Propane Cylinder Installation:

1. Remove cap from end of Propane cylinder (sold separately).

2. Cap should be kept on cylinder when not in use to prevent dirt
and debris from entering Regulator/Valve.

3. Check end of cylinder attachment for dirt and debris. Clean out
if necessary.

4. Insert threaded end of Propane Cylinder into Regulator/Valve
and hand-tighten turning cylinder clockwise as shown below.
DO NOT USE TOOLS! Over tightening can damage threads
on Regulator/Valve.

5. Perform a leak test.

Propane Cylinder Removal:

1. Turn regulator OFF.

2. Allow Grill to cool.

3. Remove the propane cylinder by turning counter-clockwise until
disengaged from the Regulator/Valve.

4. Install cap on cylinder. Cap should be kept on cylinder when not in
use to prevent dirt and debris from entering Regulator/Valve.

Leak Testing (1 lb. Disposable)

IMPORTANT!

• During leak test, keep grill away from open flames or sparks
and do not smoke. Grill must be leak tested outdoors in a well
ventilated area.

Leak test must be repeated each time gas cylinder is replaced

•

or after storage.

Materials needed include clean paint brush and 50/50 soap and
water solution. Use mild soap and water.

household cleaning agents.

Damage to components can

result.

Be sure on regulator is in "OFF" position.

1. control knob

Brush soapy solution onto between gas cylinder

2. connection

and regulator at .

(A)

If growing bubbles appear, there is a leak. Retighten
connection and repeat steps 1 and 2.

Turn propane
cylinder
CLOCKWISE to
install.

Propane Cylinder

(not included)

Do not use

- A disconnected LP cylinder in storage or being transported
must have a safety cap installed. Failure to use safety cap as
directed may result in serious personal injury and/or property
damage.

- Do not store an LP cylinder in enclosed spaces such as a

4

If you cannot stop a leak, remove gas
cylinder from regulator and check for

A

damaged threads, dirt and debris on
regulator and gas cylinder. Also check to
see if anything is obstructing flow of gas at
regulator and gas cylinder openings.
Remove any obstruction that may be
found and repeat leak test.

If threads are
damaged on either regulator or gas
cylinder, replace.

Order new parts by
giving the serial, model number and name
of items needed to the Grill Service Center
at .

1-800-232-3398

CAUTION

SPIDER ALERT!

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 burner.

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 burner tube obstructing the flow of
gas to the burner. The backed-up gas can ignite in the burner tube.
This is known as a flashback and it can damage your grill and even
cause injury.

Match Lighting Instructions

Important! Raise lid to open position.

Attempting to light burner with lid closed may cause an
explosion. Do not expose any part of your body or clothing
directly above cooking area when lighting.

1. Read all instructions before lighting.

2. From the right side of the grill, place lighted wooden match
through lighter/ventilation holes in right side of the grill.

3. While holding match next to the burner, turn control knob to
the HIGH position. Grill will ignite.

4. If ignition does NOT occurs in 5 seconds, turn the burner
controls OFF, wait 5 minutes and repeat the lighting
procedure.

5. Observe burner flames through openings in heat distribution

plate. Make sure burner ignites and stays lit on both sides.

6. Preheat grill for 10 minutes with lid closed. Using control

knob on Regulator/Valve, adjust flame to desired height for
cooking.

To prevent flashbacks and ensure good performance the burner and
burner tube should be removed from the grill and cleaned before
use whenever the grill has been idle for an extended period.

IF YOU EXPERIENCE THE FOLLOWING:

1. Smell gas.

2. Burner will not light.

3. A small yellow flame from burner (should be blue).

4. Fire coming from around or behind control knob.

STOP!
IMMEDIATELY TURN OFF GAS AT LP CYLINDER!

1. Wait for grill to cool.

2. Use a 12” pipe cleaner to clean out the burner tube.

Igniter Lighting Instructions

Important! Raise lid to open position.
Do not lean over the grill while lighting.

Attempting to light burner with lid closed may cause an
explosion. Do not expose any part of your body or clothing
directly above cooking area when lighting.

1. Read all instructions before lighting.

2. Open lid during lighting

3. Turn control knob to HIGH position.

4. Push igniter button rapidly.

5. If ignition does NOT occurs in 5 seconds, turn the burner
controls OFF, wait 5 minutes and repeat the lighting
procedure.

6. Observe burner flames through openings in heat distribution

plate. Make sure burner ignites and stays lit on both sides.

7. Preheat grill for 10 minutes with lid closed. Using control

knob on Regulator/Valve, adjust flame to desired height for
cooking.

CAUTION

If the burner flame should be extinguished
accidentally, turn the control knob to the
OFF position and open the lid. DO NOT
press the ignitor button. Wait 5 minutes
before attempting to relight the grill.

CAUTION

CAUTION

CAUTION

CAUTION

If ignition does NOT occur in 5 seconds, turn the

If ignition does NOT occur in 5 seconds, turn the

If ignition does NOT occur in 5 seconds, turn the
burner control OFF, wait 5 minutes and repeat the

burner control OFF, wait 5 minutes and repeat the

burner control OFF, wait 5 minutes and repeat the
lighting procedure. If the burner does not ignite with

lighting procedure. If the burner does not ignite with

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

the valve open, gas will continue to flow out of the

the valve open, gas will continue to flow out of the
burner and could accidently ignite with risk of injury.

burner and could accidently ignite with risk of injury.

burner and could accidently ignite with risk of injury.

Burner Flame Check

Light burner. Make sure burner stays lit while rotating the
control knob from HIGH to LOW.
to each use.

High

Low

Always check flame prior

5