Thermos 461821707 Product Manual

THIS GRILL IS FOR OUTDOOR USE ONLY.

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

461821707 • 80009773 • 03-15-07

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.

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.

MODEL 461821707 • PRODUCT GUIDE

2 • 461821707

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

CAUTION

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

Call Grill Service Center for Help and Parts

• If you need assistance with your product or warranty parts call

1-800-435-5194. 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

1-800-435-5194 and one of our friendly and knowledgeable
agents will be glad to assist you.

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.

DANGER

Safety Symbols

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

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.

CAUTION

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

Model Number

Serial Number

Date Purchased

IMPORTANT: Fill out the product record information below.

See rating label on grill for serial number.

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.

Installation Safety Precautions

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

regulator/valve assembly supplied. 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, 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. Keep any electrical
cords and/or 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 only. Do
not modify for use in any other location. Modification will result
in a safety hazard.

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 .......................................13-20

Troubleshooting..................................21-23

Limited Warranty. ...................................24

Registration Card . . . ................................27

461821707 • 3

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.

• 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.

DANGER

USE AND CARE

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

• 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). 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

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 • 461821707

LP Cylinder Valve

Retainer Strap

Dust
Cap

LP cylinder in upright position for vapor withdrawal

WARNING

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

Connecting Regulator to the LP Cylinder

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.

Safety Relief Valve

Nipple has to be centered
into the LP cylinder valve.

OPD Hand Wheel

Type 1 outlet with
thread on outside

c

k

w

o

l

i

s

e

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.

Strap and Cap

LP Cylinder Exchange

• 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.

s Do not use household cleaning agents. Damage to gas

train components can result.

Brush soapy solution onto areas indicated by arrows

in figure below.

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.

461821707 • 5

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!

tS raight

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

Leak Testing Valves, Hose and Regulator

1. Turn all grill control knobs to OFF.

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.

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 • 461821707

• 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!

WARNING

Sideburner Hose

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..

• 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.

WARNING

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.

sClean grill often, preferably after each cookout.

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!

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.

461821707 • 7

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.

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.

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

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. 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.

sDo not use citrisol, abrasive cleaners, de-greasers 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 non-abrasive scouring
powder for stubborn stains.

• Painted surfaces: Wash with mild detergent or non-abrasive
cleaner and warm soapy water. Wipe dry with a soft non­abrasive cloth.

OFF

OFF

OFF

8 • 461821707

Sideburner Ignitor Lighting

s Do not lean over grill while lighting.

1. Turn on gas at LP cylinder.

2. Turn sideburner knob to HI, push IGNITOR button.

3.

Sideburner Match Lighting

If sideburner does NOT light, turn knob to OFF, wait 5 minutes,
then repeat lighting procedure.

1. Turn on gas at LP cylinder.

2. Place lit match near burner.

3. Turn sideburner knob to HI. Be sure burner lights and stays lit.

Ignitor Lighting

s Do not lean over grill while lighting.

1. Open lid during lighting.
2a.
2b. To ignite side burner, turn side burner knob to HI .

3. Push and hold ELECTRONIC IGNITION button.

4.

5.

To ignite, turn left knob to PRE-HEAT . Go to step 3.

If ignition does NOT occur in 5 seconds, turn the burner
controls OFF, wait 5 minutes, and repeat the lighting
procedure.
To ignite right burner, turn right knob to PRE-HEAT.

6. If ignitor does not work, follow match lighting instructions.

Match-Lighting

s Do not lean over grill while lighting.

1. Open lid during lighting.

2.

3.

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

Place lit match into match holder, then into side of grill bottom
(as shown below).

Push in and turn ELECTRONIC IGNITION button to PRE­HEAT. Be sure burner lights and stays lit.

After Lighting: Turn knobs to HI for warm-up.

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.

3.

4.

5.

6.

7.

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

8. electrode

9. heat tents

grease cup

10.

Remove cooking grate and heat tent.
Under grill remove grease cup, disconnect ignitor wire from
burner.
Inside grill remove burner assembly (B), clean ceramic
portion of electrode with rubbing alcohol and a swab.
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.
If grill is to be stored, coat burner lightly with cooking oil.
Wrap in protective cover to keep insects out.
If not storing grill after cleaning, replace burner into grill
bottom.

Reattach ignitor wire to .
Reposition and cooking grate. Reattach clean

to grease clip.
Before cooking again on grill, perform a “Leak Test” and
“Burner Flame Check”.

CAUTION

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.

461821707 • 9

SPIDER ALERT!

GAS COLLECTOR

BOX & IGNITOR

VALVE

CONTROL PANEL

BURNER

VENTURI

LIFT OUT

BURNER ASSEMBLY

AIR

SHUTTER

SPIDER WEBS

INSIDE VENTURI

SPIDER WEBS

INSIDE VENTURI

CLEAN OUT

VENTURI

REMOVE
BURNER

CLIPS

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.

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.

B

A

Valve

Correct burner-to-valve engagement

Burner Tube

Food Safety

Food safety is a very important part of enjoying the outdoor
cooking experience. To keep food safe from harmful bacteria,
follow these four basic steps:

Clean: Wash hands, utensils, and surfaces with hot soapy water

before and after handling raw meat and poultry.

Separate: Separate raw meats and poultry from ready-to-eat

foods to avoid cross contamination. Use a clean platter and
utensils when removing cooked foods.

Cook: Cook meat and poultry thoroughly to kill bacteria. Use a

thermometer to ensure proper internal food temperatures.

Chill: Refrigerate prepared foods and leftovers promptly.

For more information call: USDA Meat and Poultry Hotline at
1-800-535-4555 In Washington, DC [phone], 10:00 am­4:00 pm EST.

How To Tell If Meat Is Grilled Thoroughly

• Meat and poultry cooked on a grill often browns very fast on the

outside. Use a meat thermometer to be sure food has reached
a safe internal temperature, and cut into food to check for
visual signs of doneness.

• Whole poultry should reach 180° F; breasts, 170° F. Juices
should run clear and flesh should not be pink.

• Hamburgers made of any ground meat or poultry should reach
160° F, and be brown in the middle with no pink juices. Beef,
veal and lamb steaks, roasts and chops can be cooked to 145°
F. All cuts of pork should reach 160° F.

• NEVER partially grill meat or poultry and finish cooking later.
Cook food completely to destroy harmful bacteria.

• When reheating takeout foods or fully cooked meats like hot
dogs, grill to 165° F, or until steaming hot.

10 • 461821707

461821707 • 11

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; 6,935,327; 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 D504,048. Canada: 87743; 87744; 92607; 92608 and 1,316,424. Other Patents Pending. Assembly instructions © 2006.

PARTS LIST – Model No. 461821707

Key Qty Description . ..................Part #

A 1 Firebox. . . . . ................80011600

B 1 Valve/Hose/Regulator . . . . . . . . . 80011602

C 1 Control Panel . . . . . . . . . . . . . . . . 80012280

D 2 Control Knobs . . . . . ..........80008245

E 1 Electronic Ignition Module . . ....7000160

F 2 Axle Bolt. . . . ................80011619

G 1 Left Cart Assy w/match holder. . . 80011604

H 1 Burner Assembly . . . . . . . . . . . . . 80011601

I 2 Wheels. . . . . . . . . . . . . . .......80008000

J 1 Right Cart Leg ...............80011605

K 2 Leg Extenders . . . . . . . . . . . . . . . 80008291

L 1 Bottom Shelf . . . . . . . . . . . . . . . . 80011606

M 1 Back Support Brace. . .........80011607

N 1 Tank Retainer. . . .............80008294

O 1 Front Panel . . . . . . ...........80011608

P 1 Side Shelf . . . . ..............80011609

Q 1 Lid . . . . . . . . . . . . . . . . . . . . . . . . 80011610

R 1 Logo Plate Assembly . . . . . . . . . . 80006249

S 1 Handle Assembly. . . . . . . . . . . . . 80011612

Handle Spacer...............................80009103

T 1 Sideburner Frame . . . . . . . . . . . . 80011613

U 1 Sideburner Pan . . . . . .........80011614

V 1 Sideburner Grate . . . ..........80010163

W 1 Tool Holder. . ................80011615

X 1 Sideburner Valve Cup . . . . . . . . . 80011616

Y 1 Sideburner . .................80010176

Z 1 Sideburner Knob . . . . . . . . . . . . . 80010161

Key Qty Description ...................Part #

AA 1 Heat Tent . . . . . . .............80008273

BB 1 Cooking Grate . . . . . . . . . . . . . . . 80009772

CC 1 Swing Away . . ...............80008275

DD 2 Lower Hinge. . . . . . . . . . . . . . . . . 80011618

EE 2 Upper Hinge. . . . . . . . . . . . . . . . . 80011617

FF 1 Grease Cup . . . ..............80000271

GG 1 Clip, Grease Cup .............80000272

1 Product Manual, English . . . . . . . 80009773

1 Hardware Pack . . . . . . . . . . ....80009105

4 Hitch Pin
6 #10-24 Plastic Wing Nut
5 T-Wing Screw
8 #10-24x1/2” Machine Screw
4 #10-24x1-1/4” Machine Screw
7 #10-24x2” Carriage Bolt
2 Hinge Pins
8 #10-24x3/8” Machine Screw
22 #10-24 Flange Nut
28 Ø5 Silicon Washer
2 Axle Bolt
6 #10-24x2” Machine Screw
3 #10-24 Metal Wing Nut
2 Insulation Washer
1 Burner Clip

1 Screwdriver

12 • 461821707

PARTS DIAGRAM – Model No. 461821707

Q

EE

H

R

CC

DD

S

BB

AA

A

X

B

V

U

T

P

Y

Z

W

M

C

G

F

I

N

E

D

GG

FF

J

L

KF

O

461821707 • 13

ASSEMBLY – Model No. 461821707

2

1

Attach back support brace to legs with four #10-24x2" carriage bolts and #10-24 Plastic wing nuts.

A Attach right leg assembly to bottom shelf with 2 #10-24x2" carriage bolts and #10-24 Plastic wing nuts.
B Push end caps into the bottom of the right legs.
C Place left leg assembly into bottom shelf. Insert axle bolts into wheels, legs and bottom shelf. Secure

with hitch pins.

#10-24x2”
Carriage Bolt

Qty: 2

1” Hitch Pin

Qty. 2

Axle Bolt

Qty: 2

#10-24

Plastic Wing Nut

Qty: 2

Back Support Brace

Bottom

Shelf

"Cone" side of wheel against leg

A

B

C

Right Leg Assembly

End Cap

Wheel

Left Leg Assembly

#10-24x2”

Carriage Bolt

Qty: 4

#10-24

Plastic Wing Nut

Qty: 4

14 • 461821707

3

4

Place valve/hose/regulator onto control panel. Attach with #10-24x3/8" machine screws. NOTE: Make sure the two valve stems are
centered in their clearance holes; otherwise, this can cause main burner level problems. Snap the electronic ignition module into the
control panel as shown.

#10-24x3/8"

Machine Screw

Qty: 2

Valve/Hose/Regulator

Electronic Ignition Module

A Place bottom of front panel into three slots in the bottom shelf.
B Attach front panel to legs with four #10-24x2" machine screws and #10-24 flange nuts.

Bck f ata oCr

A

B

#10-24x2”

Machine Screw

Qty: 4

#10-24

Flange Nut

Qty: 4

461821707 • 15

6

A Place fireboxonto cart, make sure the regulator hosehangs insidecartand control panel overlaps front panel.Attach to cart with

#10-24x1-1/4" machine screws, Silicon washers and #10-24 flange nuts.

B Place

machine screws and silicon washers.

burner assembly into firebox makingsure valvesare inside the burner tubes. Attach to firebox with #10-24x3/8"

C Attach ignitor wireto electronicignition module.

Attach control panel to fireboxusing #10-24X3/8" machine screws, silicon washers and #10-24 flange nuts.

#10-24X3/8"
Machine Screw
Qty: 4

Silicon Washer

Qty: 4

Control Panel

Firebox

Qty: 6

Silicon Washer

#10-24

Flange Nut

Qty: 4

Firebox

Front Panel

#10-24x1-1/4"

Machine Screw

Qty: 4

#10-24

Flange Nuts

Qty. 4

A

B

Correct burner-to-valve engagement

Burner Assembly

C

5

#10-24x3/8"

Machine Screw

Qty: 2

16 • 461821707

7

A Attach tool holder to front leg using two #10-24x2" machine screws and #10-24 flange nuts. Place sideburner pan into

frame and attach with a #10-24x2" carriage bolt and #10-24 metal wing nut in back and a T-wing screw in front.

B Attach sideburner valve cup. Place sideburner into hole. Make sure side burner valve is inside sideburner tube. Fasten sideburner

with a wing nut. Attach sideburner igntior wire to electronic ignition module.

C Place sideburner knob and grate.

Sideburner

Sideburner

Valve

Cup

Sideburner Grate

Sideburner

Knob

B

C

B

#10-24 X 2”

Machine Screw

Qty. 2

#10-24

Metal Wing Nut

Burner Clip

Qty. 1

Qty: 1

#10-24

T-Wing Screw

Qty: 1

Correctly assembled vale in sideburner tube

Tool

Holder

Sideburner Frame

Metal

Wing Nut

Flange Nut

T-Wing

Screw

Sideburner Pan

#10-24x2" Carriage Bolt

#10-24x2"

Machine Screw

#10-24x2”

Carriage Bolts

Qty: 1

#10-24

Flange Nut

Qty: 2

461821707 • 17

9

Attach lower lid hinges to back of firebox using #10-24x1/2" machines screws, silicon washers and #10-24 flange nuts per hinge.The
center flat portion of the hinge should be at the bottom (see inset).

#10-24X1/2’

Machine Screw

Qty: 4

Qty: 8

silicon Washer

#10-24

Flange Nuts

Qty. 4

Lower
Hinge

Center flat portion
of hinge on bottom.

8

Attach side shelf with #10-24 T-wing screw.

#10-24

T-Wing Screw

Qty: 4

18 • 461821707

10

Attach handle to front of lid with silicon washers and #10-24 wing nuts. Upper lid hinges attach to back with #10-24x1/2"
machine screws, fiber washers and #10-24 flange nuts.

#10-24 Wing Nut

Qty. 2

#10-24X1/2’

Machine Screw

Qty: 4

Qty: 10

Silicon Washer

#10-24

Flange Nuts

Qty. 4

Insulation Washer

Qty:2

Handle

Lid

Upper Lid Hinge

11

Place lid assembly onto firebox, aligning hinges. Hinges on lid fit inside hinges on firebox. Secure with

hinge pins and hitch pins.

Hinge Pin

Qty. 2

1” Hitch Pin

Qty. 2

A Insert ends of Swing Away pivot wire into holes in sides of grill lid. Insert ends of Swing Away leg wire into holes in sides of firebox.

NOTE: Pivot and leg wires, running side-to-side, should be under wires running front-to-back. If pivot and leg wires are on top,
Swing Away is installed upside-down.

B Place AAA battery into electronic ignition with the negative (-) side facing outward. P

Push control knobs onto valves.

ush button onto ignitor module and

turn right 1/4 turn to lock in place.

13

Back of button

Turn 1/4

Correct position

Swing Away

Leg

Pivot Wire

461821707 • 19

12

Cooking Grate

Heat Tent

Place heat tent onto V-shaped bar rests inside firebox. Place cooking grate onto firebox.

+

_

B

A

Tank Wire

15

Insert tank wire into holes in bottom shelf of the cart.

Hang grease cup clip from bottom of firebox and place grease cup into grease clip.
bottom of cylinder into bottom shelf. Rotate tank wire up to secure cylinder.

LP CYLINDER IS SOLD SEPARATELY. Fill and leak check the cylinder before attaching to grill and regulator (see Use & Care
Section). See Use & Care section of this manual to perform the "Burner Flame Check" and for important safety instructions

before using.

Tank collar opening must face to front of grill. Set

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

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.

CAUTION

Failure to install grease cup clip and
cup will cause hot grease to drip from
bottom of grill with risk of fire or
property damage.

20 • 461821707

14

Grease

Cup Clip

Grease Cup

EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.

Emergencies

Problem

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.

Burner(s) will not light
using ignitor.

Continued on next
page.

Possible Cause

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.

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.

• Wire and/or electrode covered with
cooking residue.

• Wires are loose or disconnected.

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

Prevention/Solution

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 cup, and other
surfaces.

• 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.”

• 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 (if featured):

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

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

• Reconnect wires or replace electrode/wire assembly.

• Replace ignitor wire/electrode assembly.

Troubleshooting

461821707 • 21

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.

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).

Possible Cause

ELECTRONIC IGNITION:

• No spark, no ignition noise.

• No spark, some ignition noise.

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

PIEZO PUSH-BUTTON AND ROTARY:

• Push-button sticks at bottom.

• Rotary knob rotates without clicking.

• Sparking between ignitor and electrode.

• 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.

• 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.

• Some dealers have older fill nozzles
with worn threads.

• Grease buildup or food particles in
end(s) of carryover tube(s).

Prevention/Solution

• See Section I of Electronic Ignition System.

• See Section II of Electronic Ignition System.

• See Section III of Electronic Ignition System.

• Replace ignitor.

• Replace knob.

• Inspect wire insulation and proper connection. Replace wires if
insulation is broken.

• 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.

• 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.

• 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.

22 • 461821707

Troubleshooting - Electronic Ignition

Problem (Ignition)

SECTION I

No sparks appear at
any electrodes when
ignition button is
pushed; no noise can
be heard from spark
module.

SECTION II

No sparks appear at
any electrodes when
ignition switch is
pushed; noise can be
heard from spark
module.

SECTION III

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

Possible Cause

• Battery not installed
properly.

• Dead battery.

• Button assembly not
installed properly.

• Faulty spark module.

• Output lead
connections not
connected.

• Output lead
connections not
connected.

• Arcing to grill away
from burner(s).

• Weak battery.

• Electrodes are wet.

• Electrodes cracked or
broken “sparks at
crack”.

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?

• 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.

Prevention/Solution

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

• Replace battery with new AAA-size 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.

• 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 AAA-size alkaline
battery.

• Use paper towel to remove moisture.

• Replace cracked or broken electrodes.

–+

461821707 • 23

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.

Upon consumer supplying proof of purchase as provided herein, Manufacturer will repair or replace the parts listed below which are proven
defective during the applicable warranty period. Parts required to complete such repair or replacement shall be free of charge to you except for
shipping costs. The original consumer-purchaser will be responsible for all shipping charges of 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 reasonable proof of your date of purchase. Therefore, you should retain your sales slip or invoice and register
your new product immediately. Defective or missing parts subject to this limited warranty will not be replaced without registration or proof of purchase.
Register online at http://www.charbroil.com or complete and return via mail the Product Registration Card located on the last page of the Use & Care
manual included with this product and retain your sales receipt for proof of purchase.

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.

If an original replacement part is not available, a comparable replacement part will be sent. You will be responsible for all shipping charges of
parts replaced under the terms of this limited warranty.

ITEMS MANUFACTURER WILL NOT PAY FOR:

1. Service calls to your home.

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

3. Damage resulting from accident, alteration, misuse, abuse, fire, flood, acts of God, improper installation, installation not in accordance with

electrical or plumbing codes, or use of products not approved by the manufacturer.

4. Any food loss due to product failures.

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

6. Pickup and delivery of your product.

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

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

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

DISCLAIMER OF IMPLIED WARRANTIES; LIMITATION OF REMEDIES

Repair or replacement of defect parts is your exclusive remedy under the terms of this limited warranty. Manufacturer will not be responsible for
any consequential or incidental damages arising from the breach of either this limited warranty or any applicable 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 documented purchase price of the product paid by the original consumer.

This warranty only applies to units purchased from an authorized retailer and or re-seller.

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 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 consumer­purchaser 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 write to:

Char-Broil Consumer Relations

P. O. Box 1240

Columbus, GA 31902-1240

Consumer returns will not be accepted unless a valid Return Authorization is first acquired by calling 1-800-241-7548 and then clearly marked
on the outside of the package and the package is shipped freight/postage pre-paid to the address above.

All Parts - 1 year

LIMITED WARRANTY

24 • 461821707

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intentionally

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461821707 • 25

Page

intentionally

blank

26 • 461821707

Please register your grill online at:

(If you register online, you do not need to send in this registration card.)

WWW.GRILLREGISTRATION.COM

Chimenea

/ Envíelo a:

La parrilla estaba ensamblada

461821707 • 27

Char-Broil, LLC Printed in China • Columbus, GA 31902 •

STOP

Should you encounter a problem with our product

CALL US FIRST

Do not return this product to the store.

WE CAN HELP

GRILL SERVICE CENTER

1-800-435-5194

HOURS 8AM-6PM EST Mon-Fri

Please ensure your warranty registration is complete.

Grilling Safety Checklist

Read and understand owners manual.
Never overfill LP cylinder. Overfilled cylinders may cause freeze-up of

regulator.
Check tubes for spider webs. Ensure valves are correctly installed in

burner tubes.
Always ensure control knobs are in OFF position and regulator is

attached to tank BEFORE opening tank valve to avoid low flames.
Perform leak test regularly.

Thank You for Your Purchase!