Char-Broil 500X User Manual

07201396

04201101

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,
or 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

All surfaces can be hot during use. Use protection
as required to prevent burning.

Do not use this unit on or near combustible surfaces
or structures such as wood decks, dry leaves or
grass, vinyl or wood siding, etc.

SEE OWNERS MANUAL FOR IMPORTANT SAFETY
INFORMATION.

Model Number 08301388-26

WARNING

CARBON MONOXIDE HAZARD
Burning charcoal inside can kill you. It gives off

carbon monoxide, which has no odor. NEVER burn
charcoal inside homes, vehicles or tents.

NEVER LEAVE FIRE UNATTENDED!
Do not allow small children near flame. Hot embers

can fly out in breezy conditions. Adequate fire
extinguishing material should be readily available.

CAUTION

Some parts may contain sharp edges. Wear
protective gloves if necessary.

Read and follow all safety statements, warnings,
assembly instructions and use & care directions
before attempting to assemble and cook.

Tools needed for assembly:

Adjustable Wrench (not provided)
Screwdriver (not provided)

If you have questions or need assistance during assembly, please call .

To insure your satisfaction and for follow-up service, register your grill online at www.grillregistration.com

1-800-241-7548

08301388-26 - 42804609 (07-16-10)

TABLE OF CONTENTS

Grill Service Center. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Parts List/ Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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.

DANGER

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

With any type of live fire cooking, allow enough time to build a
fire and get the grill up to temperature.

Build a fire using either charcoal briquettes, lump charcoal, or
wood chunks. Briquettes offer a very good source of heat, and
are readily available in the marketplace. Most briquettes are
manufactured using a combination of wood charcoal, coal
powder, and a processing binder. Lump charcoal is a premium
form of charcoal because it is made of only wood. Lump
charcoal burns hotter and longer than briquettes, and imparts
no chemical flavors to the food being cooked. For a more robust
smoke flavor using briquettes or lump charcoal, try adding
several wood chunks to the fire. Wood chunks are available in a
variety of natural flavors, and can be used alone or in addition to
charcoal. As a general rule, any hardwood that bears a fruit or
nut is suitable for cooking. However, different woods have very
different tastes.

Prior to cooking on your grill, the following steps should be
taken to season the interior steel. This will seal the inside
surfaces with wood smoke and resin, helping to prevent
corrosion. First, brush all interior surfaces with vegetable oil.
Next, build a small fire on the fire grate inside the firebox, being
sure not to lay coals against the walls. After the fire becomes
established, close the grill lid and position both dampers
approximately 1/4 open. Sustain this fire for at least 2 hours.

The unit is now ready for cooking!

Maintenance

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.

Grilling

Position the fire grate in the grill. Build a fire on top of the fire
grates using either charcoal briquettes, lump charcoal, or wood
chunks. Keep the grill lid open, until the fire has established
itself and is ready for cooking. Spread out coals as required,
insert cooking grates, and start grilling. Remember, grilling is
done over the top of the fire. Use the dampers to regulate the
fire and heat. Open the dampers to increase temperature; close
dampers to decrease temperatures. The grill lid can remain
open or closed. Refer to recipes for required cooking times and
temperatures.

When finished cooking, and the unit has adequately cooled,
clean out all remaining ashes. Ashes collect moisture, which
can lead to premature rusting and decay. Periodically coating
the interior surfaces with vegetable oil will aid in the protection
of your unit. Also, occasional touch up of the exterior paint will
be required. Black, high-temperature spray paint is
recommended. Never paint the interior of the unit.

Cooking Surface: 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.

Page 2

PARTS LIST

Key Qty Description

A 1 LID ASSEMBLY
B 1 BOTTOM ASSEMBLY
C 1 ASH PAN
D 1 WIRE FIRE GRATE
E 1 FRONT HANDLE KIT
F 2 SIDE HANDLE KIT
G 2 COOKING GRID
H 4 LEG KIT

I 1 FRAME, CLEAN OUT DOOR

J 2 FIRE GRATE HANGER
K 2 VENT PLATE KIT
L 2 WIRE STOP, LID
M 1 GRATE LIFTER TOOL
N 1 LOGO PLATE KIT
O 1 TEMPERATURE GAUGE
P 1 DOOR, CLEAN OUT
Q 8 LEG END CAP

NOT Pictured

… 1 HARDWARE BAG
… 1 ASSEMBLY INSTRUCTION

K

K

K

H

C

N

O

P

I

B

E

A

G

J

M

F

F

L

D

Q

Page 3

First, pick a suitable location to work. Open the carton and slit the corners. This will give a protective surface upon which to
start the assembly. During assembly, refer to the attached Hardware List near the back of this manual.

Remove the packaged parts from inside the Grill and lay the
Grill on its back. Attach Ash Door Frame to the front of Grill
Bottom using four #10-24x1/2” Flat-Head Machine Screws
and Flange Nuts.

Ash Door Frame

Attach Ash Door to Frame using two
Hinge Pins and Cotter Pins.

Ash Door

Hinge

Attach two Spacers and Side Handles to Grill Bottom
using two 1/4-20x2 ½”Machine Screws, Insulated

Washers, and 1/4-20 Flange Nuts per side.

Side Handle

Spacer

Insulated Washer

Attach four Legs using two 1/4-20x2” Machine Screws
and 1/4-20 Flange Nuts per leg.

Leg

Page 4

Slide Ash Pan into front of Grill Bottom.

Ash Pan

Open Lid and attach two Fire Grate Hangers to Fire Grate
(hooks point inward toward Grate).
Lower into Grill Bottom and hang from Tabs on each side.

Fire Grate
Hanger

Tab

Fire Grate

Place Cooking Grids into Grill Bottom.
Note: use the provided Grate Lifting Tool to lift hot
Cooking Grates.

Cooking Grids

Page 5

Attach two Spacers and Lid Handle to Grill Lid using two
1/4-20x2 ½”Machine Screws, Insulated Washers, and 1/4-20
Flange Nuts.

Lid Handle

Insulated Washer

Spacer

Insert Vent Knobs into side of Grid Lid from the outside.
Inside the Grill Lid, slide a Vent Plate onto the Knob stud
followed by a Vent Spring and a #10-24 Hex Nut.
Tighten just enough to allow Vent to slide freely from side to
side.

Vent Knob

Vent Plate

Vent Spring

Install Temperature Gauge by placing the stem through the
large hole in front of the Grill Lid. Attach the nut provided
until snug against the Lid.

Temperature Gauge

Attach the Logo Plate by inserting the two pins into the
small holes on the front of the Grill Lid.
From the inside of the Lid, press the Logo Plate Clips onto
the pins until they are snug against the Lid.

Logo Plate

Page 6

HARDWARE LIST

Hardware is shown actual size. You may have spare hardware after assembly is complete.

Insulated Washer 1/4-20 Flange Nut #10-24 Flange Nut #10-24 Hex Nut Vent Spring

Qty: 6 Qty: 14 Qty: 4 Qty: 2 Qty: 2

Small Cotter Pin

Qty: 2

Logo Plate Clip

Qty: 2

1/4-20x2 ½”

Machine Screw

Qty: 6

1/4-20 x 2”

Machine Screw

Qty: 8

Qty: 2

Hinge Pin

Qty: 2

Handle SpacerVent Knob

Qty: 6

#10-24x1/2”

Flat-Head

Machine Screw

Qty: 4

MOST SURFACES ON THIS UNIT ARE HOT WHEN IN USE.

USE EXTREME CAUTION. KEEP OTHERS AWAY FROM UNIT.

ALWAYS WEAR PROTECTIVE CLOTHING TO PREVENT INJURY.

WARNING

Page 7

LIMITED WARRANTY

This warranty only applies to units purchased from an authorized retailer. 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.

SCOPE OF COVERAGE PERIOD OF COVERAGE TYPE OF FAILURE COVERAGE

All Parts

*Note: A dated sales reciept WILL be required for warranty service.

The original consumer-purchaser will be responsible for all shipping charges for 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 proof of your date of purchase. Therefore, you should retain your sales slip or invoice. Registering your product is not a
substitute for proof of purchase and the manufacturer is not responsible for or required to retain proof of purchase records.

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.

RUST is not considered a manufacturing or materials defect.

90 days from date of purchase*

ITEMS MANUFACTURER WILL NOT PAY FOR:

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

2. Service calls to your home.

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

4. Damage, failures, or operating difficulties resulting from accident, alteration, careless handling, misuse, abuse, fire, flood,
acts of God, improper installation or maintenance, installation not in accordance with electrical or plumbing codes, or use

of products not approved by the manufacturer.

5. Any food loss due to product failures or operating difficulties.

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

7. Pickup and delivery of your product.

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

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

DISCLAIMER OF IMPLIED WARRANTIES and LIMITATION OF REMEDIES

Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. In the event of parts availability issues,
the manufacturer reserves the right to substitute like or similar parts that are equally functional.

Manufacturer will not be responsible for any consequential or incidental damages arising from the breach of either this limited warranty or any
applicable implied 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 purchase price of the

product paid by the original consumer.
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 foth 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 consumer-purchaser
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.

PERFORATION, MANUFACTURING,
AND MATERIAL DEFECTS ONLY

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

Consumer returns will not be accepted unless a valid Return Authorization is first acquired. Authorized returns are clearly marked on the outside of
the package with an RA number and the package is shipped freight/postage pre-paid. Consumer returns that do not meet these standards will be
refused.

Page 8

write to:

Consumer Relations

P. O. Box 1240

Columbus, GA 31902-1240

WS_1 Rev03

NOTES:

Page 9

NOTES:

Page 10

Warranty Registration Department
P.O. Box 1240
Columbus, GA 31902-1240

REGTEMP REV02

Page 11