Thermos 461240504 User Manual

To insure your satisfaction and for follow-up service,

register your grill online at

www.grillregistration.com

461240504 • 80001916 • 05-24-04

WARNING

FOR YOUR SAFETY

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

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

FOR YOUR SAFETY
If you smell gas:

1. Shut off gas to the appliance.

2. Extinguish any open flame.

3. Open lid.

4. If odor continues, immediately call your

gas supplier or your fire department.

Call Grill Service Center For Help And Parts

• If you need help or warranty parts call 1-800-241-7548 U.S. or
1-800-387-6057 CANADA.
Business hours: Open 24 hours – Seven days a week.

• To order non-warranty replacement parts or accessories (

cover, cleaners, paint

1-706-565-2121.

IMPORTANT: Fill out the product record information below.

) call 1-800-993-2677 or send a FAX to

grill

Installation Safety Precautions

•

Use grill only with LP (propane) gas and the regulator/valve
assembly supplied.

•

Grill installation must conform with local codes, or in their
absence with

Z223.1 CAN/CGA-B149.2 Propane Installation Code

Handling and storage of LP cylinders must conform to LP Gas

NFPA/ANSI 58.

Code 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 Canadian
Electrical Code, CSA C22.1.

fuel supply hoses away from any hot surfaces.

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

Safety Symbols

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

National Fuel Gas Code, NFPA 54 / ANSI

or .

or

Keep any electrical cords and/or

DANGER

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

Model Number

Serial Number

See rating label on grill for serial number.

Date Purchased

CAUTION

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

WARNING

CALIFORNIA PROPOSITION 65
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.

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.

2 • 461240504

TABLE OF CONTENTS

WARRANTY

For Your Safety ......................................2

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

Product Record Information ............................2

Installation Safety Precautions ..........................2

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

Warranty ...........................................3

Parts List...........................................4

Parts Diagram.......................................5

Assembly ........................................6-15

Use and Care ...................................16-24

Registration Card ...................................25

To insure your satisfaction

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
with the date of purchase.

Stainless steel - Limited Lifetime against perforation
Burners - 3 years
Electronic ignition (excluding battery) - 3 years
Remaining parts (excluding battery) - 1 year

Manufacturer will not be responsible for failure or damage resulting
from use, accident, alteration, misuse, transportation, commercial
use, abuse, hostile environments, improper installation or
installation not in accordance with local codes.

or part found to be defective during its respective warranty period.
Manufacturer will require return of the part(s) claimed to be
defective, for its inspection, freight or postage prepaid.
Manufacturer may require reasonable proof of purchase and
suggests that receipts be retained.

corrosion or discoloring by heat, abrasive and chemical cleaners or
any tools used in the assembly or installation of the appliance. This
limited warranty does not include the cost of any inconvenience,
personal injury or property damage due to failure of the product.

and for follow-up service,

GIVEN BY THE MANUFACTURER AND IS IN LIEU OF ALL

register your grill

online at:

www.grillregistration.com

Stainless Steel Use and Care

Stainless steel grills can provide many years of reliable
service and an attractive appearance in normal outdoor
exposure. Consider the following tips to extend the
appearance of your stainless steel grill:

• Cooking smoke from normal use of the grill will eventually

coat and discolor the stainless steel surface. Periodic

cleaning of the surface with readily available stainless

steel cleaners is recommended. (In coastal areas, small

rust pits may develop on the surface of your grill that

cannot be fully removed by a cleaner.)

• Periodic cleaning of the cooking grates also helps

decrease the risk of a grease fire which can irreversibly

darken the stainless steel surface. (Please note that the

integrity of the steel is not affected by the flame, only the

appearance.)

OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR
A PARTICULAR PURPOSE OR USE.

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 consumer­purchaser.

incidental or consequential damages, so the above limitations or
exclusions may not apply to you. This limited warranty gives you
specific legal rights as set for herein. You may also have other
rights which vary from state to state. In the state of California only, if
refinishing or replacement of the product is not commercially
practicable, the retailer selling this product or the Manufacturer will
refund the purchase price paid for the product, less the amount
directly attributable to use by the original 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.

limited warranty, you should write to:

Manufacturer warrants to the original consumer-purchaser

This limited warranty is for replacement of defective parts only.

Manufacturer will, at its option, refinish or replace any product

This limited warranty does not cover scratches, dents,

THIS EXPRESS WARRANTY IS THE SOLE WARRANTY

Neither dealers nor the retail establishment selling this product

NOTE: Some states do not allow an exclusion or limitation of

If you wish to obtain performance of any obligation under this

Consumer Warranty / P.O. Box 1240

Columbus, GA 31902-1240

461240504 • 3

PARTS LIST – Model No. 461240504

Key Qty Description Part #

A 1 Lid Insert........................80000503

B 1 Lid End Cap - Left ................80000501

C 1 Lid End Cap - Right ...............80000502

D 1 Lid Handle ......................80000506

E 1 Thermometer ....................80000096

F 1 Bezel for Thermometer.............80000097

G 1 Logo Plate ......................80001002

H 1 Grill Bottom Front Assembly.........80000651

I 1 Grill Bottom Rear Assembly .........80000018

J 1 Bottom End Cap - Left .............80000021

K 1 Bottom End Cap - Right ............80000022

L 3 Main Burner .....................80000023

M 3 Flame Tamer ....................80000273

N 1 Burner Brace/Carryover ............80001438

O 1 Ignitor Assembly..................80000653

Key Qty Description Part #

1 Side Shelf Assembly .............80000808

AA 1 Side Shelf.......................80000060

BB 1 Side Shelf Panel..................80000518

CC 1 Cart Side w/Panel, Left.............

80000066

DD 1 Cart Side w/Panel, Right ...........80000071

EE 1 Back Panel ......................80000080

FF 4 Caster Socket....................80000076

GG 1 Bottom Shelf.....................80000317

HH 1 Bottom Rail......................80000800

I I 1 Door Assembly - Left ..............80000805

JJ 1 Door Assembly - Right .............80000802

KK 2 Door Handle .....................80000086

LL 1 Grease Tray .....................80000831

MM 1 Door Brace ......................80000801

P 1 Manifold Heat Shield ..............80000031

Q 1 Control Panel ....................80001909

R 4 Control Knob ....................80000035

S 3 Bezel for Main Control Knob ........80000034

T 1 Manifold/Hose/Regulator Assembly . . . 80000036

1 Sideburner Shelf Assembly........80000809

U 1 Sideburner Frame ................80000045

V 1 Sideburner Lid ...................80000316

W 1 Sideburner Pan ..................80000051

X 1 Sideburner Electrode ..............80000055

Y 1 Sideburner Control Panel...........80001301

Z 1 Sideburner Assembly ..............80000277

NN 1 SwingAway Warming Rack .........80000263

OO 1 Condiment Basket - Left............80000266

PP 1 Condiment Basket - Right ..........80000267

QQ 2 Locking Caster ...................80000268

RR 2 Fixed Caster.....................80000269

SS 1 Grease Receptacle................80000834

TT 1 Cooking Grate Set ................80000293

UU 1 Sideburner Grate .................80000282

1 Hardware Pack...................80001915

1 Warranty Hardware Pack ...........80002136

1 Product Guide ...................80001916

Certified Grill Parts And Accessories®, Char-Broil and Design®, Char-Broil (Gas Grill Briquettes)®, Char-Diamonds®, Cooking Zone and Design®, Diamond Flame®, Executive Chef®, Faststart®, Flare
Fighter®, FlavorMaster®, Gas Grill Silouette and Design®, H2O Smoker®, Lava Flame®, MasterFlame®, MasterFlame Precision Cooking System®, PowerSpark®, Quantum®, VIP®, PrecisionFlame and
Design®, Sierra®, and TruFlame® are registered Trademarks of the W.C. Bradley Company. Thermos® is a registered trademark of the Thermos Company and its affiliates.

Artisan Collection by Char-Broil ™, C3 and Design™, Char-Broil and Design™, Flame Design™, FlavorTents™, Grill 2 Go™, Grillin’Stick™, Keeper of the Flame™, Keepers of the Flame™, Natural Grip™,
Outdoor Cooking Collection and Design™, Patio Bistro™, PrecisionFlame™, Pro-Check™, QuickSet Grills and Design™, SmokerTents™, The Big Easy™, The Minute Grill™, The Edge™, The Tuscan
Collection™, and The Urban Grill™ are Trademarks of the W.C. Bradley Company. Universal Grill Parts and Design™ is a trademark of the Thermos Company and its affiliates.

Protected under one or more of the following U.S. Patents: 4,598,692; 4,624,240; 4,747,391; 4,747,391; 4,817,583; 4,924,846; 4,989,579; 5,003,960; 5,076,256; 5,076,257; 5,090,398; 5,109,834; 5,224,676;
5,277,106; 5,421,319; 5,441,226; 5,452,707; 5,458,309; 5,566,606; 5,566,606; 5,579,755; 5,582,094; 5,613,486; 5,649,475; 5,706,797; 5,711,663; 5,765,543; 5,931,149; 5,996,573; 6,095,132; 6,135,104;
6,173,644B1; 6,279,566; 6,397,731; 6,418,923; 6,439,222; 6,523,461; D282,619; D339,714; D341,292; D343,337; D358,059; D361,466; D364,535; D372,637; D373,701; D377,735; D383,035; D397,910;
D405,643; D405,643; D406,005; D406,009; D413,043; D413,229; D413,229; D414,982; D415,388; D416,164; D416,441; D416,441; D417,587; D422,516; D423,274; D423,876; D428,303; D435,396; D436,004;
D438,059; D438,060; D438,427; D439,110; D442,505; D443,179; D443,354; D447,384; D447,385; D447,909; D448,610; D448,614; D448,615; D448,616; D448,975; D449,492; D451,759; D456,202S; D460,313,
D461,359 and D477,501. Canada: 87743; 87744; 92607; 92608 and 1,316,424. Other Patents Pending.

4 • 461240504

PARTS DIAGRAM – Model No. 461240504

TT

M

TT

I

J

M

L

F

E

G

A

C

B

M

D

K

NN

N

AA

L

L

BB

P

UU

H

T

Q

LL

Z

S

S

S

SS

V

R

R

O

U

MM

Y

X

CC

DD

R

FF

W

RR

QQ

FF

FF

EE

FF

RR

QQ

PP

GG

HH

OO

JJ

II

KK

KK

461240504 • 5

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.

ASSEMBLY – Model No. 461240504

1

First

, remove door brace from rear legs. Place door
brace onto front legs as shown. Tabs on brace fit
inside legs. Secure brace to back of front legs using
one self-tap screw on each side.(ZZ)

4.2X10mm

Door brace

Rear view

Left front leg

Rear view

2

Attach , non-locking

locking casters to front legs

casters to rear legs. Tighten casters using the
caster wrench provided.

ZZ

Locking casters
on front legs.

6 • 461240504

Caster
wrench

3

This step requires two people to lift and position grill
head onto cart.

Carefully lower the grill head onto the cart between the
two braces. Align the two holes on each side of the grill
head with the two holes on each brace. Make sure the
regulator hose is hanging outside the cart.

Align
holes

Regulator
hose

4

Secure grill head to leg braces using four screws

, lock washers , and flat washers .

(AAA) 7mm (BBB) 7mm (CCC)

Screws must be attached from of grill head into brace.

Do not fully tighten screws until side shelf and sideburner
shelf are assembled.

CCC

BBB

AAA

inside

1/4-20x3/4”

461240504 • 7

5

Place side shelf over right cart legs. Lip of shelf should fit between grill bottom and leg brace.
Secure shelf brackets to cart legs using one screw , lock washer

, and flat washer on each bracket.

(BBB) 7mm (CCC)

1/4-20x3/4” (AAA) 7mm

CAUTION

SHARP EDGES! Wear gloves if necessary.

AAA

6

Place sideburner shelf over left cart legs. Lip of shelf should fit between grill
bottom and leg brace. Secure shelf brackets to cart legs using one

1/4-20x3/4” (AAA) 7mm (BBB) 7mm
(CCC)

Fully tighten screws inside grill bottom at this time.

screw , lock washer , and flat washer

on each bracket.

CAUTION

SHARP EDGES! Wear gloves if necessary.

CCC

Repeat on front bracket

BBB

AAA

BBB

Repeat on front bracket

8 • 461240504

CCC

7

Remove the two screws and washers from the sideburner valve bracket.

Place sideburner valve under front of sideburner control panel so that
valve stem comes through large hole. Secure valve to panel using the
two screws and washers you removed from the valve bracket. Press
control knob onto valve stem.

First, remove
screws and
washers from
bracket.

8

Insert sideburner into shelf, placing end of burner over
sideburner valve. Valve should be in center hole of burner
tube. Make sure pin on bottom of burner is in center hole
in shelf bracket. Secure burner to bracket with two

#10-24x3/8” (DDD) 5mm (EEE)

and flat washers .

5mm (FFF) See illustration below for

correct burner-to-valve engagement

screws , lock washers ,

.

Sideburner
valve

Sideburner

FFF

EEE

DDD

Pin
in hole

Correct
burner-to-valve
engagement

Valve should be
in center hole in
burner tube.

461240504 • 9