Char-Broil T-22D, 466251413, 466241013, 463241013 Product Manual

PRODUCT GUIDE
MODEL 466251413

T-22D

IMPORTANT: Fill out the product record information below.

Serial Number

See rating label on grill for serial number.

Date Purchased

For support and to register your
grill, please visit us at

www.charbroil.com

IM PO RTA NT: Re fe r to the
in st ru ct io ns i nsi de w he n
con ve rt in g th is g ri ll to
Na tu ra l Ga s.

If you have questions or need
assistance during assembly,
please call 1-888-430-7870.

© 2013 Char-Broil, LLC Columbus, GA 31902

Printed in China

Assembly instructions © 2013

09/25/12 • G352-001-070801

TABLE OF CONTENTS

For Your Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

DANGER

Use and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Parts Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-21

Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-25

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-28

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Safety Symbols

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

WARNING

If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, keep away from the
appliance and immediately call your gas
supplier or your fire department.

WARNING

1. Do not store or use gasoline or other
flammable liquids or vapors in the vicinity of
this or any other appliance.

2. An LP cylinder not connected for use shall not
be stored in the vicinity of this or any other
appliance.

WARNING: Indicates a 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.

DANGER

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

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

For residential use only. Do not use for commercial

For residential use only. Do not use for commercial

cooking.

CAUTION

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

CAUTION

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

2

THIS GRILL IS FOR OUTDOOR USE ONLY.

WARNING

CAUTION

CALIFORNIA PROPOSITION 65

1. Combustible by-products produced when using
this product contains 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.

Installation Safety Precautions

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

regulator/valve assembly supplied. If your grill is Dual Fuel ready,
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.

• All electrical accessories (such as rotisserie) must be
electrically grounded in accordance with local codes, or

National Electrical Code, ANSI / NFPA 70 or Canadian
Electrical Code, CSA C22.1. Keep any electrical cords and/or

fuel supply hoses away from any hot surfaces.

• This grill is safety certified for use in the United States and/or
Canada only. Do not modify for use in any other location.
Modification will result in a safety hazard.

WARNING

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.

Using pots larger than 6 quarts in capacity could
exceed weight limit of the
side burner shelf
or side shelf,
resulting in failure
of grill cart
components.

CAUTION

Grease Fires

• 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.

• If grill has not been regularly cleaned, a grease fire can
occur that may damage the product. Pay close attention
while preheating or burning off food residue to insure
that a grease fire does not develop. Follow instructions
on General Grill Cleaning and Cleaning The Burner
Assembly to prevent grease fires.

• The best way to prevent grease fires is regular cleaning

of the grill.

NOTE: DO NOT over tighten screws and washers that

come into contact with porcelain coated surfaces. Over
tightening may cause the porcelain coating to crack and
break, resulting in exposed metal that will be prone to rust.

3

USE AND CARE

DANGER

• NEVER store a spare LP cylinder under or near
the appliance or in an enclosed area.

LP Cylinder

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

•Use LP cylinders only with these required measurements: 12"

(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.

•LP cylinders must be constructed and marked in accordance

with specifications for LP cylinders of the U.S. Department of
Transportation (DOT) or for Canada, CAN/CSA-B339,
cylinders, spheres and tubes for transportation of dangerous
goods. Transport Canada (TC). See LP cylinder collar for
marking.

•LP cylinder 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 cylinders equipped with this type of valve.

•LP cylinder must be arranged for vapor withdrawal and include
collar to protect LP cylinder valve. Always keep LP cylinders in
upright position during use, transit or storage.

OPD Hand Wheel

• Never fill a cylinder beyond 80% full.

• An over filled or improperly stored cylinder is a
hazard due to possible gas release from the
safety relief valve. This could cause an intense
fire with risk of property damage, serious injury or
death.

• If you see, smell or hear gas escaping,
immediately get away from the LP
cylinder/appliance and call your fire department.

LP Cylinder Removal, Transport and Storage

•Turn OFF all control knobs and LP cylinder valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Loosen cylinder screw beneath bottom shelf or

disconnect other retention means, then lift PL cylinder up and

and out of cart. Install safety cap onto LP cylinder valve.
Always use cap and strap supplied with valve.

Failure to use safety cap as directed may result in serious
personal injury and/or property damage.

•A disconnected LP cylinder in

storage or being transported
must have a safety cap installed (as shown).
Do not store an LP cylinder in enclosed spaces
such as a carport, garage, porch, covered
patio or other building. Never leave an LP cylinder
inside a vehicle which may become overheated
by the sun.

•Do not store an LP cylinder in an area where children play.

LP Cylinder Valve

Safety
Cap

Retainer Strap

LP cylinder 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 Cylinder Filling

•Use only licensed and experienced dealers.

•LP dealer must purge new cylinder before filling.

•Dealer should NEVER fill LP cylinder more than 80% of LP

cylinder volume. Volume of propane in cylinder will vary by

temperature.

•A frosty regulator indicates gas overfill. Immediately close LP
cylinder 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 cylinder, contact an LP dealer or call a

local fire department for assistance. Check the telephone
directory under “Gas Companies” for nearest certified LP
dealers.

4

LP Cylinder Exchange

Connecting Regulator to the LP Cylinder

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

those reputable exchange companies that inspect, precision fill,
test and certify their cylinders. Exchange your cylinder only

for an OPD safety feature-equipped cylinder as described
in the "LP Cylinder" section of this manual.

•Always keep new and exchanged LP cylinders in upright

position during use, transit or storage.

•Leak test new and exchanged LP cylinders BEFORE

connecting to grill.

•Place dust cap on cylinder valve outlet whenever the cylinder is
not in use. Only install the type of dust cap on the cylinder valve
outlet that is provided with the cylinder valve. Other types of caps

or plugs may result in leakage of propane.

LP Cylinder Leak Test

For your safety

•Leak test must be repeated each time LP cylinder is exchanged

or refilled.

•Do not smoke during leak test.

•Do not use an open flame to check for gas leaks.

•Grill must be leak tested outdoors in a well-ventilated area,

away from ignition sources such as gas fired or electrical
appliances. During leak test, keep grill away from open flames
or sparks.

•Use a clean paintbrush and a 50/50 mild soap and water

solution.

Brush soapy solution onto areas indicated by arrows

in figure below.

▲ Do not use household cleaning agents. Damage to gas

train components can result.

1.LP cylinder must be properly secured onto grill. (Refer to
assembly section.)

2.Turn all control knobs to the OFF position.

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

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

cap and strap supplied with valve.

c

k

w

o

i

l

s

e

Strap and Cap

OPD Hand Wheel

Type 1 outlet with
thread on outside

Safety Relief Valve

C

f

f

O

Do not use a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.

WARNING

If “growing” bubbles appear do not use or move the LP
cylinder. Contact an LP gas supplier or your fire
department!

5.Hold regulator and insert nipple into LP

cylinder valve. Hand-tighten the
coupling nut, holding regulator in a
straight line with LP cylinder valve so
as not to cross-thread the connection.

Nipple has to be centered
into the LP cylinder valve.

5

Leak Testing Valves, Hose and Regulator

1.Turn all grill control knobs to OFF.

Straight

Hold coupling nut and regulator
as shown for proper connection
to LP cylinder 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 cylinder
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 cylinder.

3.Completely open LP cylinder 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, or other similar

fittings on your grill.

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

NOTE: Sideburner
shelf fascia not
shown for clarity.

5.If “growing” bubbles appear, there is a leak. Close LP
cylinder valve immediately and retighten connections. If leaks
cannot be stopped do not try to repair. Call for replacement

parts.

6.Always close LP cylinder valve after performing leak test by

turning hand wheel clockwise.

NOTE: Your grill
may NOT be
equipped with a
sideburner.

6

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.)

•

Do not cover grates with aluminum foil or any other
material. This will block burner ventilation and create
a potentially dangerous condition resulting in
property damage and/or personal injury.

•

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

Before opening LP cylinder valve, check the coupling nut for

▲

tightness.
When grill is not in use, turn off all control knobs and LP

▲

cylinder valve.
Never move grill while in operation or still hot.

▲

Use long-handled barbecue utensils and oven mitts to avoid

▲

burns and splatters.
Maximum load for sideburner and side shelf is 10 lbs.

▲

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.

If 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.
Keep ventilation openings in cylinder enclosure (grill cart) free

▲

and clear of debris.
Do not store objects or materials inside the grill cart

▲

enclosure that would block the flow of combustion air to the
underside of either the control panel or the firebox bowl.
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".

▲

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!

• 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.

• Always close LP cylinder valve and remove
coupling nut before moving LP cylinder from
specified operation position.

Main Burner Ignitor Lighting

▲ Do not lean over grill while lighting.

1. Turn OFF all gas burner control valves.

2. Turn ON gas source or tank.

3. Open lid during Lighting.

4. To ignite any main burner, turn the main burner control
knob to the position.

5. Push and hold ELECTRONIC IGNITOR button until the
burner lights.

6. Once burner has ignited , turn knob to desired setting.

7. If Ignition does not occur in 5 seconds, turn the burner
control to OFF, wait 5 minutes, and repeat the lighting
procedure.

8. Repeat steps 4 through 7 for the other main burners.

Lighting instructions continued on next page.

7

WARNING

Turn controls and gas source or tank OFF when not
in use.

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.

Main Burner Match-Lighting

▲ Do not lean over grill while lighting.

1. Turn OFF all gas burner control valves.

2. Turn ON gas at LP cylinder.

3. Open lid during lighting.

4. Place match into match holder (hanging from side of cart).

Light match, place into lighting hole on right or left side of
firebox.

5. Push in and turn right or left knob to position. Be
sure burner lights and stays lit.

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

procedure.

7. Light other burner by pushing knob in and turning to
position.

Burner Flame Check

•Remove cooking grates and troughs. Light burners, rotate
knobs from to . You should see a smaller flame in

position than seen on . Perform burner flame check

on sideburner, also. 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 OFF position. Turn LP cylinder off by

turning hand-wheel clockwise to a full stop.

Ignitor Check

• Turn gas off at LP cylinder. Press and hold electronic ignitor

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

Valve Check

• Important: Make sure gas is off at LP cylinder before

checking valves. Knobs lock in OFF position. To check

valves, first push in knobs and release, knobs should spring
back. If knobs do not spring back, replace valve assembly

before using grill. Turn knobs to LOW 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 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.

▲ 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.

• Stainless steel surfaces: To maintain your grill’s high quality

appearance, wash with mild detergent and warm soapy water

and wipe dry with a soft cloth after each use. Baked-on grease
deposits may require the use of an abrasive plastic cleaning
pad. Use only in direction of brushed finish to avoid damage.
Do not use abrasive pad on areas with graphics.

• 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.

8

CAUTION

SPIDER ALERT!

SPIDER AND WEBS

INSIDE BURNER

If your barbeque is getting hard to light or
the flame is weak, check and clean the
venturis and burners.

Storing Your Grill

• Clean cooking grates.

• Store in dry location.

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

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

• Store grill indoors ONLY if LP cylinder 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.

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 cylinder.

2. Remove cooking grates and troughs.

3. Remove cotter pins and carryover tubes from front of burners.

4. Remove cotter pin and lift burner to disengage from
bracket on firebox.

5. Use flat blade screwdriver to pry off electrode from burner.
Electrode should remain in firebox.

6. Carefully lift each burner up and away from valve openings.

We suggest three ways to clean the burner tubes. Use the one
easiest for you.

(A) Bend a stiff wire (a light weight coat hanger works well)

into a small hook. Run the hook through each burner
tube several times.

(B) Use a narrow bottle brush with a flexible handle (do not

use a brass wire brush), run the brush through each
burner tube several times.

(C) Wear eye protection: Use an air hose to force air into

the burner tube and out the burner ports. Check each
port to make sure air comes out each hole.

7. Wire brush entire outer surface of burner to remove food

residue and dirt.

8. Clean any blocked ports with a stiff wire such as an open

paper clip.

9. Check burner for damage, due to normal wear and corrosion

some holes may become enlarged. If any large cracks or
holes are found replace burner.

VERY IMPORTANT: Burner tubes must reengage valve

openings. See illustrations at right.

Attach electrode to burner.

10.

11. Carefully replace burners.

12. Attach burners to brackets on firebox.

13. Reposition carryover tubes and attach

to burners. Replace troughs and
cooking grates.

Correct

burner-to-valve

engagement

Firebox

Electrode

Carryover tube

Firebox burner
bracket

Pry off electrode with a
flat blade screwdriver

9

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

Stainless Burner
Firebox and Lid
All Other Parts

*Note: A dated sales receipt 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.

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.

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.

Limited Lifetime
2 years from date of purchase*
1 year from date of purchase*

write to:

Consumer Relations

P. O. Box 1240

Columbus, GA 31902-1240

PERFORATION, MANUFACTURING,
AND MATERIAL DEFECTS ONLY

10

PARTS LIST

Key Qty Description

A 1 TOP LID

B 2 BEZEL, F/ LID HANDLE

C 1 HANDLE F/ TOP LID

D 1 LOGO PLATE, TEMP GAUGE
E 2 RUBBER BUMPER, ROUND, W/ HARDWARE, F/

TOP LID

F 2 RUBBER BUMPER, LID

G 1 FIREBOX

H 2 COOKING GRATE

I 1 WARMING RACK

J 2 MAIN BURNER, F/ FIREBOX

K 2 ELECTRODE W/ WIRE/COLLECTOR, F/ MAIN

BURNER

L 1 CARRY OVER, F/ MAIN BURNER

M 2 SIDE SHELF, FIXED

N 1 LEFT SIDE SHELF, FOLDING

O 1 RIGHT SIDE SHELF, FOLDING

P 1 FASCIA, F/ LEFT SIDE SHELF

Q 1 FASCIA, F/ RIGHT SIDE SHELF

R 1 MAIN CONTROL PANEL

S 1 HOSE VALVE REGULATOR ASSY

T 1 MATCH HOLDER

U 2 BEZEL, F/ CONTROL KNOB

V 2 CONTROL KNOB

W 1 CART UPPER BACK PANEL

X 1 HEAT SHIELD, F/ TANK

Y 1 FRONT DOOR BRACE

Z 1 ELECTRONIC IGNITION MODULE

AA 1 BUTTON, F/ ELECTRONIC IGNITION MODULE

BB 1 IGNITER SWITCH MODULE

CC 1 DOOR, NO HANDLE

DD 1 DOOR HANDLE

EE 1 CART LEFT SIDE PANEL

FF 1 CART RIGHT SIDE PANEL

GG 1 BOTTOM SHELF

HH 1 TANK SCREW, F/ BOTTOM SHELF

II 2 CASTER, LOCKING

JJ 2 CASTER, FIXED

KK 1 HARDWARE F/ TOP LID ASSEMBLY

LL 1 TROUGH, FIREBOX

Key Qty Description

… 1 DOOR MAGNET

… 1 CASTER PIN

… 1 HARDWARE PACK

… 1 ASSEMBLY MANUAL, ENGLISH

… 1 ASSEMBLY MANUAL, FRENCH

NOT Pictured

NOTE: Some grill parts shown in the assembly steps may differ slightly in appearance from
those on your particular grill model. However, the method of assembly remains the same.

11

PARTS DIAGRAM

KK

W

A

D

E

F

H

B

I

C

L

EE

G

J

LL

J

K

S

X

M

U

M

O

T

V

N

Q

R

AA

Z

P

FF

BB

DD

Y

GG

JJ

12

II

HH

CC

ASSEMBLY

1

Place bottom shelf upside down. Insert Caster Pin into the caster mounting plate to lock it in place, shown A. Spin the caster
clockwise into the threads on the bottom shelf until secure. Remove the Caster Pin and repeat for remaining casters. Make
sure the two locking casters are secured at the rear and the non-locking casters are secured at the front. After all 4 casters
are secured remove the Caster Pin and save for future maintenance.

Locking caster

Non-lock caster

A

Caster pin

Front

Bottom shelf

2

Make sure side
panels are pushed as
far to the rear of
bottom shelf as
possible before fully
tightening screws.

Attach side panels to bottom shelf using three 1/4-20x1/2” screws per panel.
IMPORTANT: Panel with magnet must be on Left side of bottom shelf.

Left side panel

Magnet

Rear

1/4-20x1/2"

screw

Right side panel

Front

13

3

This step requires two people to lift and position grill head onto cart. Carefully lower the grill head onto the
cart, aligning slots at bottom of grill head with posts on cart side panels. Make sure the regulator hose is

hanging inside the cart.

Grill head

Regulator hose

Left side panel

Right side panel

4

On back of grill, place upper back panel between side panels. Secure upper back panel in lower holes, using one

1/4-20x1½” screw on each side.

1/4-20x1 ½"

screw

Upper back panel

Slots at bottom

14

5

Control panel

Insert front brace under control panel and between cart panels. Make sure door hinge pin is on the top side and facing the
front. Secure front brace in upper holes using one 1/4-20x1½” screw and Fiber washer on each side. Secure front brace in
lower holes using one 1/4-20x1½” screw on each side,

6

Fiber

washer

Front brace

Attach right side fascia to right side shelf using two #10x3/8" screws.
Only right side shelf shown for assembly, install left side fascia to left side shelf in the same way.

Hinge pin

1/4-20x1 ½"

screw

1/4-20x1 ½"

screw

Right side fascia

Screwdriver must pass through holes on
the side shelf bracket.

#10x3/8" screw

Right side shelf

15

7

Attach foldable side shelf brackets to the tracks under right side shelf using one shoulder screw and 1/4" nut
each side, shown A/B.

Pull foldable side shelf outward and press it down, shown C.
Push foldable side shelf toward right side shelf until they meet, shown D.

Only right side shelf shown for assembly, repeat above steps to Install left side shelf with foldable side
shelf.

A

B

Track

Right side shelf

Front Side,
No Gear Trax Holes

Bracket

TM

1/4"Nut

Foldable side shelf

Rear Side, With
Gear Trax Holes

TM

Shoulder screw

C

Foldable side shelf

16

D

Right side shelf

Foldable side shelf

8

Insert flange on right side shelf into side shelf brackets on side of firebox, shown A.

Attach right side shelf using two 1/4-20x1/2"screws and 1/4" nuts, shown B.

Attach front of shelf using three #8x3/8" self-tapping screws and large flat washers, shown C.
Note: For ease of assembly, use a long-blade screw driver for this step.

Attach rear of shelf using one 1/4-20x1 ½"screw, shown D.

Only right side shelf shown for assembly, repeat above steps to install left side shelf.

A

Bracket

C

Right side shelf

1/4-20x1/2" screw

B

1/4" nut

D

#8x3/8" self-tapping

screw

Large flat

washer

Note: For ease of assembly, use a long-blade screw
driver for this step

1/4-20x1 ½" screw

17

9

Inside of cart, insert rear tabs (w/o holes) of tank heat shield into slots on the bottom of upper back panel, shown A.
Attach front tabs (w/ holes) of tank heat shield under front brace using two #8x3/8" self-tapping screws, shown B.

Upper back panel

A

Connect each of the wires from main burner electrodes into the back of Electronic Ignition Module. Total (2)

10

connections. Connect the two wires [(a) and (b)] from switch wiring harness into the back of the Electronic
Ignition Module. Total (2)connections, shown A. Unscrew the cap and nut from electronic ignition module. Attach
electronic ignition module to the cart left side panel with the nut, shown B. Insert AA battery into electronic
ignition module, negative (—) end first. Replace the cap, shown C.

Insert tabs into slots

Left side panel

Right side panel

Tank heat shield

Note: Some parts omitted for
clarity of illustration

Front brace

#8x3/8" self-tapping

screw

Leave wires outside when attaching
tank heat shield to front brace.

B

A

(a)

1

2

(b)

NOTE: Switch terminals are larger than electrode terminals
and should only be installed in location shown as (a), (b).

B

C

Cap

Nut

-

+

AA Battery

Electronic

ignition module

Left side panel

18

11

Attach door handle to door using two #10-24x3/8” screws.

#10-24x3/8"

screw

12

Insert hinge pin on bottom of door into hole in bottom shelf. Press upper hinge pin in front brace, align hinge hole
on top of door and release hinge pin into door.

PRESS

Top of
door

Hinge pin
on bottom
of door

19

13

Install trough into fire box as shown. Align pins at front of trough with the holes at front of fire box.

Trough

14

Trough pin

Place cooking grates onto firebox as shown. Insert the three wire ends at rear of warming rack into holes in back of firebox.
Front wires of warming rack rest on sides of firebox.

warming rack

Cooking grate

20

15

LP CYLINDER IS SOLD SEPARATELY. Fill and leak check the cylinder before attaching to grill and regulator (see
Use & Care section). Once cylinder has been filled and leak checked, place cylinder into hole in bottom shelf.

Make sure cylinder valve is facing front of grill. Secure cylinder with cylinder screw under bottom shelf.

See Use & Care section of this manual to perform the burner Flame Check and for important safety instructions

before using.

Cylinder screw at rear of cart

Cylinder screw

Always keep LP cylinders in upright position during
use, transport and storage.

LP Cylinder

(not included)

CAUTION

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

Regulator

21

Consumer must purchase Natural Gas Conversion Kit 4584625 to convert this grill to natural
gas. Use the following instructions instead of instructions found in conversion kit

Main Burner Conversion

1

2

Make sure all Control Knobs are in the OFF position, LP Tank Valve is closed, Tank is disconnected from Regulator and
removed from Grill.
Remove Warming Rack, Cooking Grates and Troughs.

Your grill may differ from illustration shown. This portion of the manual covers a variety of grill styles. Use pictures as
reference only. Not all steps will apply to your grill conversion.

Remove Hitch Pins and remove Carryover Tubes.
Remove Hitch Pins at back of Burners to detach Burners from Burner Brackets.
Lift back of Burner while sliding Burner out of Firebox, disengaging burners from Valves.

Burner

Hitch Pin

Front of
Firebox

3

Carryover Tube

Insert Orifice Removal Tool provided with Kit into Firebox Burner openings and unscrew Orifices from ends of Valves. Save
removed Orifices and Orifice Removal Tool for converting back to LP Tank Gas. These grill valves are designed to work
with Natural Gas once Orifices are removed. Do not replace any Main Burner Orifices when using Natural Gas.

Orifice

Hitch Pin

Firebox Burner Opening

Burner

Orifice

Valve

Front of
Firebox

22

Orifice Removal Tool

4

Pull the Burner Control Knobs off of Valve Stems.
Remove Screws and Washers that secure each Bezel to the Control Panel. Save removed Bezels for converting back to LP
Tank Gas.
Install new Natural Gas Bezels provided with Kit (see illustration below) in place of old Bezels, on Control Panel and secure
using previously removed Screws and Washers. Assure proper alignment with Control Knob before fully tightening.

Note: New Bezels will change the rotation for the Control Knob to properly control ignition and flames for your grill.

Press Control Knob back onto Valve Stems. Make adjustments to Bezels for free movement of Control Knobs.

Note: Replace only one Bezel at a time.

Main Burner
Control Knobs

Natural Gas Bezel

Screws

Valve Stem

Bezels

Insert Burners into Firebox Burner openings, then over Valves with burner crossover port holes downward, making sure

5

Burner engages Valve properly.
See below diagram.

Secure Burners to Burner Brackets with previously removed Hitch Pins. Replace Carryover Tubes and secure with Hitch

Pins previously removed. Reference illustration Step 2.

Tube Burner

Correct burner-to valve engagement

Port holes
downward

Incorrect burner-to valve engagement

80007893

23

Natural Gas Hose Conversion

Using a wrench, not provided, remove LP Regulator Hose Assembly from Manifold Connection. Save removed LP Manifold

6

Connection for converting back to LP Tank Gas.

Your Grill may differ from illustration shown.

Manifold Connection

LP Regulator Hose Assembly

Manifold Connection

Natural Gas Hose Assembly

24

WARNING

Do not use hard metal piping of any kind to connect this
type of grill to natural gas source. Use only hose
specified by manufacturer. Using hard metal piping or
convoluted metal tubing is an unsafe practice. Movement
of the grill can cause breakage of metal pipe.

Connecting Your Grill to the Natural Gas Source.

1. A professionally-installed shut-off valve between the supply piping

and the socket is recommended, but not required, by the National
Fuel Gas Code. Socket connection must be made outdoors.

2. Coat the gas supply pipe nipple with gas resistant pipe dope or
approved teflon tape. Screw socket onto gas supply pipe (house gas
source) as shown in Figure A below, and wrench-tighten.

CAUTION

The quick disconnect socket should never be connected
to the grill. Direction of gas flow is indicated on the
socket.

Quick disconnect socket House piping

4. When the quick disconnect socket and the gas hose are connected,

a valve in the socket opens automatically to permit full gas flow.
When the gas hose is disconnected, the valve in the socket instantly
and positively shuts off the flow of gas. Because the valve in the
socket positively shuts off the flow of gas, the grill can be
disconnected from the gas source by disconnecting the gas hose
from the quick disconnect socket. The socket should be left attached
to the gas source (house piping). Figure C, below, shows properly
connected hose and socket.

Figure C

With proper assembly, the gas hose cannot be removed without
pushing the quick disconnect sleeve back. To disconnect, push

sleeve back and pull plug out of sleeve (this automatically shuts off
gas).

Figure A

3. Pull back the sleeve on the quick disconnect socket and insert the

unattached end of the gas hose into the socket. Release the sleeve
and continue pushing the hose into the socket until the sleeve snaps
into the locked position. See Figure B.

Gas hose

Sleeve

Please Note: Hose and assembly are C.S.A. listed for natural gas,
manufactured gas, mixed gas and for liquefied petroleum and for
LP Gas-Air mixtures on basis of 0.64 specific gravity for 1000
BTU's per cubic foot of gas at 0.3 in. water column pressure drop.
Only ANSI Z21.54 approved hoses should be used with this grill.

The appliance and its individual shut off valve must be
disconnected from the gas supply piping system during any
pressure testing on that system at test pressures in excess of 1/2
psig (3.5kPa).

The appliance must be isolated from the gas supply piping system
by closing its individual manual shutoff valve during any pressure
testing of the gas supply piping system at test pressures equal to
or less than 1/2 psi (3.5kPa).

Figure B

25

DANGER: 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
cylinder.

Gas leaking from LP
cylinder valve.

Gas leaking between
LP cylinder 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 cylinder 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 cylinder 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 cylinder.

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

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

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

Prevention/Solution

Burner(s) will not light
using ignitor.
(See Electronic Ignition
Troubleshooting also)

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 cylinder.

• Coupling nut and LP cylinder valve not
fully connected.

ELECTRICAL ISSUES:

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

• Electrode tip not in proper position.

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

• For a grill equipped with the AUTO-CLEAN™ feature, make sure

the AUTO-CLEAN™ valve is set to “Grill”

• Turn off knobs and disconnect coupling nut from LP cylinder.
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:

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

• Wire and/or electrode covered with
cooking residue.

• Wires are loose or disconnected.

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

• Dead battery.

26

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

• Reconnect wires or replace electrode/wire assembly.

• Replace ignitor wire/electrode assembly.

• Replace with a new alkaline battery.

Troubleshooting (continued)

Problem

Burner(s) will not light
using ignitor.
(See Electronic Ignition
Troubleshooting also)

Burner(s) will not
match light.

Sudden drop in gas
flow or low flame.

Flames blow out.

Possible Cause

ELECTRONIC IGNITION:

• No spark, no ignition noise.

• No spark, some ignition noise.

• Sparks, but not at electrode or at full
strength.

• 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 cylinder
connection.

• High or gusting winds.

• Low on LP gas.

Prevention/Solution

• See Section I of Electronic Ignition System.

• See Section II of Electronic Ignition System.

• See Section III of Electronic Ignition System.

• Use long-stem match (fireplace match).

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

• Check for gas in LP cylinder.

• Turn off knobs, wait 30 seconds and light grill. If flames are still low,
turn off knobs and LP cylinder valve. Disconnect regulator.
Reconnect regulator and leak-test. Turn on LP cylinder valve, wait
30 seconds and then light grill.

• Turn off knobs and LP cylinder valve. Disconnect coupling nut from
cylinder. Reconnect and retry.

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

• Refill LP cylinder.

Flare-up.

Persistent grease fire.

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

Unable to fill LP
cylinder.

One burner does not
light from other
burner(s).

AUTO-CLEAN™

(If Equipped)

Timer does not work
(Green light does not
flash)

• 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.

• 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 cylinder. 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.

• Some dealers have older fill nozzles
with worn threads.

• Grease buildup or food particles in

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

• Clean carry-over tube(s) with wire brush.

end(s) of carryover tube(s).

Possible Cause Prevention/Solution

 Dead Battery
 Batteries installed incorrectly.
 Knob Position did not start the Clean

Cycle

 Replace batteries
 Install batteries correctly.
 Push Knob in to start the clean cycle. (Green LED should begin to

flash)

No LED’s will illuminate  Dead Battery

Red LED next to battery

 Low Battery Strength

symbol is illuminated

 Replace batteries

 Prepare to replace batteries (NOTE: Clean cycle will operate with

a weak battery.

27

Troubleshooting - Electronic Ignition

Problem (Ignition)

SECTION I

No sparks appear at

any electrodes when
Electronic Ignition Button
is pressed; no noise can

be heard from spark

module.

SECTION II

No sparks appear at

any electrodes when

Electronic Ignition Button

is pressed; noise can

be heard from spark

module.

Possible Cause

• Battery not installed
properly.

• Dead battery.

• Button assembly not
installed properly.

• Faulty spark module.

• Output lead
connections not
connected.

Check Procedure

• Check battery orientation.

• Has battery been used
previously?

• Check to insure threads are
properly engaged. Button
should travel up and down
without binding.

• If no sparks are generated
with new battery and good
wire connections, module is
faulty.

• Are output connections on
and tight?

Prevention/Solution

• Install battery (make sure that “+” and “–”
connectors are oriented correctly, with “+” end up
and “–” end down.)

• Replace battery with new alkaline battery.

• Unscrew button cap assembly and reinstall, making
sure threads are aligned and engaged fully.

• Replace spark module assembly.

• Remove and reconnect all output connections at
module and electrodes.

SECTION III

Sparks are present
but not at all
electrodes and/or not
at full strength

• Output lead
connections not
connected.

• Arcing to grill away
from burner(s).

• Weak battery.

• Electrodes are wet.

• Electrodes cracked or
broken “sparks at
crack”.

• Are output connections on
and tight?

• If possible, observe grill in
dark location. Operate
ignition system and look for
arcing between output wires
and grill frame.

• All sparks present but weak
or at slow rate.

• Has moisture accumulated
on electrode and/or in burner
ports?

• Inspect electrodes for
cracks.

• Remove and reconnect all output connections at
module and electrodes.

• If sparks are observed other than from burner(s),
wire insulation may be damaged. Replace wires.

• Replace battery with a new alkaline battery.

• Use paper towel to remove moisture.

• Replace cracked or broken electrodes.

NOTES

29

NOTES

30

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PLEASE F ILL OUT THIS CARD AND ATTACH A COPY OF YOUR SALES R ECEIPT. RETURN IT WITHIN 10 DAYS OF PURCHASE. FOR WARRANT Y SE RVICE PROOF OF PURCHASE
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COM PRA. CONSE RVE LA FACTURA. ESTA GARAN TIA ES INTRAN SFERIBLE.

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31

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