461644304
USE & CARE MANUAL
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 these
instructions with consumer.
CONSUMER: Keep this manual for future
reference.
WARNING
Read this manual before cooking on grill. Failure to follow all manufacturer’s
instructions could result in fire or explosion which could cause property damage,
personal injury or death.
Combustion by-products produced when using this product contain chemicals known
to the State of California to cause cancer, birth defects, or other reproductive harm.
461644304 Use & Care • 80000790 • 09-16-03
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WARRANTY
Manufacturer warrants to the original consumer-purchaser that this product shall be free from defects in workmanship and
materials under normal and reasonable use and correct assembly (if assembled by consumer-purchaser), for a period of one (1)
year from date of purchase.
Manufacturer will, at its option, replace any product or part found to be defective during the warranty period. Manufacturer
will require you to return the part(s) claimed to be defective, for its inspection, freight or postage prepaid.
If you wish to obtain performance of any obligation under this limited warranty, you should write to:
Consumer Warranty / P.O. Box 1240
Columbus, GA 31902-1240
Manufacturer may require reasonable proof of purchase and we suggest you keep your receipt. In the state of California
only, if replacement of the product is not commercially practicable, the retailer selling this product or 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
from which it was purchased or to any retail establishment selling this product in order to obtain performance under this
warranty.
This warranty does not include the cost on any inconvenience or property damage due to failure of the product and does
not cover damage due to misuse, abuse, accident, damage arising out of transportation of the product, or damage incurred
through commercial use of the product. This express warranty is the sole warranty given by the manufacturer and is in lieu of all
other warranties, express or implied, including implied warranty of merchantability or fitness for a particular purpose. Neither
Manufacturer dealers nor the retail establishment selling this product has any authority to make any 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-purchaser. Some states do not allow the exclusion or limitation
of incidental or consequential damages. So the above limitations or exclusions may not apply to you. This warranty gives you
specific legal rights and may also have other rights which vary from state to state.
461644304 • 3
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LP Tank
USE AND CARE
• The LP tank used with your grill must meet the following
requirements:
DANGER
• Use LP tanks only with these required measurements: 12"
(30.5cm) (diameter) x 18" (45.7 cm) (tall) with 20 lb. (9 kg.)
capacity maximum.
• Never fill the cylinder beyond 80% full. An overfilled
spare LP tank is hazardous due to possible gas
released from the safety relief valve.
• LP tanks must be constructed and marked in accordance with
specifications for LP tank of the U.S. Department of
Transportation (DOT). See LP tank collar for marking.
• The safety relief valve on the LP tank could activate,
releasing gas, and cause an intense fire with risk of
property damage, serious injury or death.
• LP tank valve must have:
• Type 1 outlet compatible with
regulator or grill.
• NEVER store a spare LP tank under or near grill or in
enclosed areas.
• Safety relief valve.
• UL listed Overfill Protection
OPD Hand Wheel
• If you see, smell or hear escaping gas, immediately get
away from the LP tank/grill and call your fire
department.
Device (OPD). This OPD safety
feature is identified by a unique triangular hand wheel. Use
only LP tanks equipped with this type of valve.
• All spare LP tanks must have safety caps installed on
the LP tank outlet.
• LP tank must be arranged for vapor withdrawal and include
collar to protect LP tank valve.
LP Tank Removal, Transport And Storage
LP (Liquefied Petroleum Gas)
• Turn OFF all control knobs and LP tank valve. Turn coupling
nut counterclockwise by hand only - do not use tools to
disconnect. Loosen tank screw beneath bottom shelf, then lift
LP tank up and out of cart. Install safety cap onto LP tank
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.
• 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 Tank Filling
LP Tank Valve
• Use only licensed and experienced dealers.
• LP dealer must purge new tank before filling.
• Dealer should NEVER fill LP tank more than 80% of LP tank
volume. Volume of propane in tank will vary by temperature.
• A frosty regulator indicates gas overfill. Immediately close LP
tank valve and call local LP gas dealer for assistance.
• Do not release liquid propane (LP) gas into the atmosphere.
This is a hazardous practice.
Safety Cap
• To remove gas from LP tank, contact an LP dealer or call a
local fire department for assistance. Check the telephone
directory under “Gas Companies” for nearest certified LP
dealers.
Retainer Strap
• A disconnected LP tank in storage or being transported must
have a safety cap installed (as shown). Do not store an LP tank
in enclosed spaces such as a carport, garage, porch, covered
patio or other building. Never leave an LP tank inside a vehicle
which may become overheated by the sun.
• Do not store an LP tank in an area where children play.
4 • 461644304
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LP Tank Exchange
Connecting Regulator To The LP Tank
• Many retailers that sell grills offer you the option of replacing
your empty LP tank through an exchange service. Use only
those reputable exchange companies that inspect, precision fill,
test and certify their cylinders. Exchange your tank only for
an OPD safety feature-equipped tank as described in the
"LP Tank" section of this manual.
1. LP tank must be properly secured onto grill. (Refer to
assembly section.)
2. Turn all control knobs, including sideburner, to the OFF
position.
3. Turn LP tank OFF by turning hand-wheel clockwise to a full
stop.
• Always keep new and exchanged LP tanks in upright position
during use, transit or storage.
4. Remove the protective cap from LP tank valve. Always use
cap and strap supplied with valve.
• Leak test new and exchanged LP tanks BEFORE
connecting to grill.
ck
LP Tank Leak Test
For your safety
OPD Hand Wheel
• Leak test must be repeated each time LP tank is exchanged or
refilled.
Type 1 outlet with
thread on outside
• Do not smoke during leak test.
Safety Relief Valve
• 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.
Strap and Cap
• 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 a POL transport plug
(plastic part with external threads)!
It will defeat the safety feature of
the valve.
s Do not use household cleaning agents. Damage to gas
train components can result.
5. Hold regulator and insert nipple into LP
tank valve. Hand-tighten the coupling
nut, holding regulator in a straight line
with LP tank valve so as not to cross-
thread the connection.
Nipple has to be centered
into the LP tank valve.
WARNING
If “growing” bubbles appear do not use or move the LP tank.
Contact an LP gas supplier or your fire department!
461644304 • 5
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Leak Testing Valves, Hose and Regulator
1. Turn all grill control knobs to OFF.
2. Be sure regulator is tightly connected to LP tank.
3. Completely open LP tank 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.
Hold coupling nut and regulator
as shown for proper connection
to LP tank 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 tank
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!
WARNING
• Do not insert any foreign objects into the valve outlet. You
may damage the valve and cause a leak. Leaking propane
may result in explosion, fire, severe personal injury, or
death.
• 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.
Rear view of grill.
• If you cannot stop a gas leak, immediately close LP tank
valve and call LP gas supplier or your fire department!
5. If “growing” bubbles appear, there is a leak. Close LP tank
valve immediately and retighten 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
of items needed to the Grill Service Center at 1-800-241-7548.
6. Always close LP tank valve after performing leak test by
turning hand wheel clockwise.
6 • 461644304
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Safety Tips
WARNING
s Before opening LP tank valve, check the coupling nut for
tightness.
For Safe Use Of Your Grill And To Avoid Serious
Injury:
s When grill is not in use, turn off all control knobs and LP tank
valve.
• Do not let children operate or play near grill.
• Keep grill area clear and free from materials that burn.
• Do not block holes in bottom or back of grill.
• Check burner flames regularly.
s Never move grill while in operation or still hot.
s Use long-handled barbecue utensils and oven mitts to avoid
burns and splatters.
s Maximum load for side shelves is 10 lbs.
• 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.
s The grease cup must be attached to grease clip and emptied
after each use. Do not remove grease cup until grill has
completely cooled.
• Do not use charcoal or ceramic briquets in a gas grill.
(Unless briquets are supplied with your grill.)
s 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.
• 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..
s Keep grill cart free and clear of debris.
s The regulator may make a humming or whistling noise during
operation. This will not affect safety or use of grill.
s If you have a grill problem see the "Troubleshooting Section".
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 tank
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.
• Apartment Dwellers:
Ignitor Lighting
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.
s Do not lean over grill while lighting.
1. Open lid. Turn on gas at LP tank.
2. Turn LEFT knob to
(Ignite).
• NEVER attempt to light burner with lid closed. A buildup
of non-ignited gas inside a closed grill is hazardous.
3. Push ignitor button rapidly (up to 5 times) to light. Be sure
burner lights and stays lit.
• Never operate grill with LP tank out of correct position
specified in assembly instructions.
4. If burner does not light, turn knob(s) to OFF, wait 5 minutes,
then try again.
• Always close LP tank valve and remove coupling nut
before moving LP tank from specified operation
position.
5. Turn RIGHT knob to
(Ignite) to light right burner.
6. If ignitor does not work, follow match lighting instructions.
461644304 • 7
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Turning Grill Off
CAUTION
• Turn all knobs to OFF position. Turn LP tank off by turning
hand-wheel clockwise to a full stop.
If burner does not light, turn knobs to OFF , wait 5
minutes, and try again. 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.
Ignitor Check
• Turn gas off at LP tank. Press ignitor button rapidly. "Click"
should be heard and spark seen each time between collector
box or burner and electrodes. See "Troubleshooting" if no click
or spark.
Match-Lighting
Valve Check
s Do not lean over grill while lighting.
1. Open lid. Turn on gas at LP tank.
• Important: Make sure gas is off at LP tank 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.
2. Place lit match into match lighting hole beneath grill bottom as
shown below.
3. Push in and turn RIGHT knob to
lights and stays lit.
(Ignite). Be sure burner
Hose Check
4. Light left burner by turning LEFT knob to
(Ignite).
• 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.
Before Your First Cookout
• Light burners, check to make sure they are lit, then close the lid
and warm up grill on (High) for 15 minutes. Curing of paint
and parts will produce an odor only on first lighting. Do not
warm up grill with knobs on
become uncomfortably hot if knobs are left on
• 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.
(Ignite). Knobs and handle may
(Ignite).
• Painted surfaces: Wash with mild detergent or nonabrasive
cleaner and warm soapy water. Wipe dry with a soft
nonabrasive cloth.
Burner Flame Check
• Remove cooking grate and VapoRISER Bar. Light burner,
rotate knobs from (High) to (Low). You should see a
smaller flame in Low position than seen on High. Always check
flame prior to each use. If only low flame is seen refer to
"Sudden drop or low flame" in the Troubleshooting Section.
High
Low
8 • 461644304
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Cleaning The Burner Assembly
CAUTION
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 tank.
2. Remove cooking grate, VapoRISER Bar, and grease cup.
3. Disconnect ignitor wire from burner electrode and remove
the two burner screws from beneath grill bottom.
4. Carefully lift burner assembly up and away from valves.
5. Clean ceramic portion of electrode with rubbing alcohol and
a swab.
6. Clean outside of burner with soap and water. Lay burner
upside down on a 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.
7. If grill is to be stored, coat burner lightly with cooking oil.
Wrap in protective cover to keep insects out.
8. If not storing grill after cleaning, replace burner into grill
bottom.
NATURAL HAZARD • SPIDERS
FACT: Sometimes spiders and other small insects climb into
the burner tubes attached to the burners. The spiders spin
webs, build nests and lay eggs. The webs or nests
can be very small, but they are very strong
and can block the flow of gas. Clean
burners prior to use after storing, at the
beginning of grilling season or after a period
of one month not being used.
Spider guards are on the air intakes in an effort to reduce this
problem, but it will not eliminate it! An obstruction can result
in a "flashback" (a fire in the burner tubes). The grill may still
light, but the obstruction does not allow full gas flow to the
burners.
IF YOU EXPERIENCE THE FOLLOWING:
1. Smell gas.
2. Burner(s) will not light.
VERY IMPORTANT: Burner tubes must reengage valve
openings. See illustrations below.
9. Attach burner to grill bottom with screws and attach ignitor
wire to burner electrode
10. Reposition VapoRISER Bar and cooking grate. Attach clean
grease cup beneath grill bottom.
11. Before cooking again on grill, perform a “Leak Test” and
“Burner Flame Check”.
3. A small yellow flame from burner (should be blue).
4. Fire coming from around or behind control knob.
STOP!
Immediately turn off gas at LP tank!
SOLUTION:
s Do not use ceramic briquets or charcoal in your gas
grill.
Wait for grill to cool.
Follow the “Cleaning The Burner Assembly” instructions.
Clean burners often. Use a 12” pipe cleaner to clean out the
burner tubes. You may also force a stream of water from a
hose nozzle through burner tubes to clean them.
Valve
Storing Your Grill
• Clean cooking grates.
• Store in dry location.
• When LP tank is connected to grill, store outdoors in a well-
ventilated space and out of reach of children.
• Cover grill if stored outdoors. Choose from a variety of grill
covers offered by manufacturer.
Burner Tube
• Store grill indoors ONLY if LP tank 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.
461644304 • 9
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Food Safety
How To Tell If Meat Is Grilled Thoroughly
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:
• 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.
Clean: Wash hands, utensils, and surfaces with hot soapy water
before and after handling raw meat and poultry.
• Whole poultry should reach 180° F; breasts, 170° F. Juices
should run clear and flesh should not be pink.
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.
• 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.
Cook: Cook meat and poultry thoroughly to kill bacteria. Use a
thermometer to ensure proper internal food temperatures.
• NEVER partially grill meat or poultry and finish cooking later.
Cook food completely to destroy harmful bacteria.
Chill: Refrigerate prepared foods and leftovers promptly.
For more information call: USDA Meat and Poultry Hotline at
1-800-535-4555 In Washington, DC (202) 720-3333, 10:00 am-
4:00 pm EST.
• When reheating takeout foods or fully cooked meats like hot
dogs, grill to 165° F, or until steaming hot.
10 • 461644304
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Troubleshooting
Problem
Possible Cause
Prevention/Solution
Burner(s) will not light
using ignitor.
• Wire and/or electrode covered with
cooking residue.
• Clean wire and/or electrode with rubbing alcohol and clean swab.
• Electrode and burner are wet.
• Electrode cracked or broken "sparks at
crack”.
• Wipe dry with cloth.
• Replace electrode.
• Wire is loose or disconnected.
• Wires are shorting (sparking) between
ignitor and electrode.
• Reconnect wire.
• Replace ignitor wire/electrode assembly.
• Bad Ignitor.
• Replace ignitor.
Burner(s) will not
match light.
• No gas flow.
• Check to see if LP tank is empty. If LP tank is not empty, refer to
"Sudden drop in gas flow".
• Coupling nut and regulator not fully
connected.
• Obstruction of gas flow.
• Turn the coupling nut about one-half to three quarters additional
turn until solid stop. Tighten by hand only-do not use tools.
• Clear burner tube(s).
• Disengagement of burner to valve.
• Is grill assembled correctly?
• Reengage burner and valve.
• Check steps in assembly instructions.
Sudden drop in gas
flow or low flame.
• Out of gas.
• Excess flow valve tripped.
• Check for gas in LP tank.
• Turn off knobs, wait 30 seconds and light grill. If flames are still low,
turn off knobs and LP tank valve. Disconnect regulator. Reconnect
regulator and leak test. Turn on LP tank valve, wait 30 seconds and
then light grill.
Flames blow out.
Flare-up.
• High or gusting winds.
• Low on LP gas.
• Excess flow valve tripped.
• Turn front of grill to face wind or increase flame height.
• Refill LP tank.
• Refer to "Sudden drop in gas flow" above.
• Grease buildup.
• Excessive fat in meat.
• Excessive cooking temperature.
• Clean grill.
• Trim fat from meat before grilling.
• Adjust (lower) temperature accordingly.
Persistent grease fire.
• Grease trapped by food buildup around
burner system.
• Turn knobs to OFF. Turn gas off at LP tank. Leave lid in position and
let fire burn out. After grill cools, remove and clean all parts.
Flashback...
(fire in burner tube(s)).
• Burner and/or burner tubes are blocked.
• Turn knobs to OFF. Clean burner and/or burner tubes.
Unable to fill LP tank.
• Some dealers have older fill nozzles
with worn threads.
• The worn nozzles don't have enough "bite" to engage the valve. Try
a second LP dealer.
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; 6,173,644; 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.
461644304 • 11
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A Division of W.C. Bradley Co. • Columbus, GA 31902
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