Permasteel 461632208, Cgpg50400s Owner's Manual

MODEL 461632208 • 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 1-800-435-5194.

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.

461632208 • 80017979 • 06-20-08

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

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.

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

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, 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,
Electrical Code, CSA C22.1.

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
Canada
Modification will result in a safety hazard.

only. Do not modify for use in any other location.

Keep any electrical cords and/or

or Canadian

and/or

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.

Serial Number

See rating label on grill for serial number.

Date Purchased

CAUTION

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

2 • 461632208

DANGER

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

WARNING

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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-24

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

To insure your satisfaction

and for follow-up service,

register your grill

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.

CAUTION

CAUTION: Indicates a potentially hazardous situation or
unsafe practice which, if not avoided, may result in minor
or moderate injury.

461632208 • 3

USE AND CARE

DANGER

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

• 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.

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

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

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)

cylinders, spheres and tubes for transportation of dangerous
goods. Transport Canada (TC).

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.

or for Canada, CAN/CSA-B339,

See LP cylinder collar for

OPD Hand Wheel

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, then
lift LP cylinder up and out of cart. 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. 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 cylinder in

storage or being transported
must have a dust 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

Dust
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 • 461632208

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.

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.
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 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.

Continued on next page.

Nipple has to be centered
into the LP cylinder valve.

461632208 • 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.

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

5. If “growing” bubbles appear, there is a leak. Close LP
cylinder valve immediately and re-tighten 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 1-800-435-5194.

6. Always close LP cylinder valve after performing leak test by
turning hand wheel clockwise.

6 • 461632208

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 cylinder valve, check the coupling nut for

tightness.

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

cylinder valve.

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

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

 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 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.

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 cylinder 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.

461632208 • 7

Ignitor Lighting

s Do not lean over grill while lighting.

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.

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

2.

(as shown below).
Push in and turn left knob to PRE-HEAT. Be sure burner

3.

lights and stays lit.

4. To ignite right burner, turn knob to PRE-HEAT.

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.

HI

LO

Turning Grill Off

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

OFF

Ignitor Check

• Turn gas off at LP cylinder. 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 cylinder 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
OFF

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.

8 • 461632208

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.

AIR

SHUTTER

LIFT OUT

BURNER ASSEMBLY

VENTURI

BURNER

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 cylinder.

2. heat tent

Remove cooking grate and .

3.

Under grill remove grease cup and disconnect ignitor wire.

4.

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

5.

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.

6.

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

7.

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

VERY IMPORTANT: Burner tubes must re-engage valve
openings. See illustration (A).

REMOVE
BURNER

CLIPS

CLEAN OUT

VENTURI

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.

SPIDER WEBS

INSIDE VENTURI

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 cylinder 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 cylinder. Storage of an outdoor
cooking gas appliance indoors is permissible only if the cylinder
is disconnected and removed from the appliance.

• 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.

8. electrode

Reattach ignitor wire to .

9. heat tent

Reposition and cooking grate. Reattach clean
grease cup

10.

Before cooking again on grill, perform a “Leak Test” and

to grease clip.

“Burner Flame Check”.

Correct burner-to-valve engagement

Valve

Burner Tube

B

A

461632208 • 9