Char Broil Charcoal Grill 461111811 User Manual

Product Guide  
Model 461111811  
IMPORTANT: Fill out the product record information below.  
Serial Number  
See rating label on grill for serial number.  
Date Purchased  
For support and to register your  
grill, please visit us at  
If you have questions or need  
assistance during assembly,  
please call 1-800-241-7548.  
Estimated assembly time: 30 minutes  
THIS GRILL IS FOR OUTDOOR USE ONLY.  
WARNING  
DANGER  
This manual contains important information necessary  
for the proper assembly and safe use of the appliance.  
If you smell gas:  
1. Shut off gas to the appliance.  
2. Extinguish any open flame.  
3. Open lid.  
Read and follow all warnings and instructions before  
assembling and using the appliance.  
Follow all warnings and instructions when using the  
appliance.  
4. If odor continues, keep away from the appliance  
and immediately call your gas supplier or your  
fire department.  
Keep this manual for future reference  
Failure to follow these instructions could result in  
fire or explosion which could cause property  
damage, personal injury or death.  
CAUTION  
Some parts may contain sharp edges — especially as  
noted in the manual! Wear protective gloves if necessary.  
WARNING  
INSTALLER/ASSEMBLER: Leave these instructions with  
consumer.  
CONSUMER: Keep this manual for future reference.  
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.  
© 2010 Char-Broil, LLC • Columbus, GA 31902 • Printed in China • Assembly Instructions © 2010  
42804627 05-18-11  
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Installation Safety Precautions  
Use grill, as purchased, only with LP (propane) gas and the  
regulator/valve assembly supplied.  
USE AND CARE  
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. Storage and handling of  
liquefied petroleum gasses must conform to LP Gas Code  
ANSI / NFPA 58. Grill is not for use in or on recreational  
vehicles and/or boats.  
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 (i.e.  
gasoline, propane, or any other flammable liquid or gas).  
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.  
Do not block holes in bottom or back of grill.  
Check burner flames regularly.  
Never use regulator from this grill with any other LP  
appliance.  
When cooking, the appliance must be on a level surface in  
an area clear of combustible material.  
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.  
Use grill only in well-ventilated space. NEVER use in  
enclosed space such as carport, garage, porch, covered  
patio, or under an overheoad structure of any kind.  
o
• Do not leave appliance unattended. Keep children and  
pets away from appliance at all times.  
Do not use charcoal or ceramic briquets in a gas grill.  
(Unless briquets are supplied with your grill.)  
Safety Tips  
This appliance is not intended for and should never be used  
as a heater.  
sThe use of alcohol, prescription or nonprescription drugs  
may impair the consumers ability to properly assemble or  
safely operate the appliance.  
• Use grill at least 2 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..  
sWhen grill is not in use, disconnect 1 lb. cylinder.  
sNever move grill while in operation or still hot. Allow the  
appliance to cool before moving or storing.  
A
2 ft. (.6m) minimum  
10 ft. recommended  
sThe 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.  
sLight burners. Check to make sure they are lit, close the lid  
and warm up grill on high for 10 minutes. Curing of paint  
and parts will produce an odor only on first lighting.  
sGrill is not intended for and should never be used as a  
heater.  
sClean 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.  
sUse long-handled barbecue utensils and oven mitts to avoid  
• Apartment Dwellers:  
burns and splatters.  
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
If the regulator frosts, turn off grill and LP cylinder valve  
immediately. This indicates a problem with the cylinder and it  
should not be used on any product. Return to supplier!  
• 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  
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LP (Liquefied Petroleum Gas)  
Propane Cylinder Installation/Removal  
Propane Cylinder Installation:  
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.  
1. Remove cap from end of Propane cylinder (sold separately).  
• LP gas is highly flammable and may ignite unexpectedly  
when mixed with air.  
2. Cap should be kept on cylinder when not in use to prevent dirt  
and debris from entering Regulator/Valve.  
3. Check end of cylinder attachment for dirt and debris. Clean out  
if necessary.  
Propane Cylinder Use (1 lb. Disposable)  
Use only cylinder marked Propane Fuel.  
Cylinder must be constructed and marked in accordance with  
the specifications for LP-gas cylinders of the U.S. Department  
of Transportation (DOT) or the National Standard of Canada,  
CAN/CSA-B339, Cylinders, Spheres and Tubes for the  
Transportation of Dangerous Goods.  
4. Insert threaded end of Propane Cylinder into Regulator/Valve  
and hand-tighten turning cylinder clockwise as shown below.  
DO NOT USE TOOLS! Over tightening can damage threads  
on Regulator/Valve.  
5. Perform a leak test.  
Turn propane  
cylinder  
CLOCKWISE to  
install.  
Save cylinder cap and reinstall when not in use.  
Cylinder supply system must be arranged for vapor  
Propane Cylinder  
(not included)  
withdrawal. Gas cylinder must be upright in use.  
Propane Cylinder Removal:  
1. Turn regulator OFF.  
2. Allow Grill to cool.  
Propane Gas Cylinders  
- Your grill is designed to operate with one 16.4 oz. disposable  
cylinder (Dot 39 Cylinder) that is 7 3/8” high (not included).  
Do not attempt to refill any 16.4 oz. disposable fuel  
cylinders.  
3. Remove the propane cylinder by turning counter-clockwise until  
disengaged from the Regulator/Valve.  
4. Install cap on cylinder. Cap should be kept on cylinder when not in  
use to prevent dirt and debris from entering Regulator/Valve.  
- The cylinder must be installed, transported and stored in an  
upright position and should not be dropped or handled  
roughly.  
Leak Testing (1 lb. Disposable) IMPORTANT!  
During leak test, keep grill away from open flames or sparks  
and do not smoke. Grill must be leak tested outdoors in a well  
ventilated area.  
- When the appliance is to be stored indoors, the propane gas  
cylinder must be disconnected from the appliance.  
Leak test must be repeated each time gas cylinder is replaced  
or after storage.  
Materials needed include clean paint brush and 50/50 soap and  
- When the propane gas cylinder is not disconnected from the  
appliance, the appliance and cylinder must be stored  
outdoors in a well-ventilated space.  
water solution. Use mild soap and water.  
Do not use  
household cleaning agents. Damage to components can  
result.  
1. Be sure control knob on regulator is in "OFF" position.  
2. Brush soapy solution onto connection between gas cylinder  
and regulator at (A).  
- The cylinder should never be transported or stored where  
temperature can reach 125 F (51 C).  
If growing bubbles appear, there is a leak. Retighten  
connection and repeat steps 1 and 2.  
- Cylinders must be stored outdoors out of the reach of  
children.  
If you cannot stop a leak, remove gas  
cylinder from regulator and check for  
- A disconnected LP cylinder in storage or being transported  
must have a safety cap installed. Failure to use safety cap as  
directed may result in serious personal injury and/or property  
damage.  
A
damaged threads, dirt and debris on  
regulator and gas cylinder. Also check to  
see if anything is obstructing flow of gas at  
regulator and gas cylinder openings.  
Remove any obstruction that may be  
found and repeat leak test. If threads are  
damaged on either regulator or gas  
cylinder, replace. Order new parts by  
giving the serial, model number and name  
of items needed to the Grill Service Center  
at 1-800-232-3398.  
- Do not store an LP cylinder in enclosed spaces such as a  
carport, garage, porch, covered patio or other building.  
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Lighting Instructions  
Important! Remove or raise lid to open position.  
Attempting to light burner with lid closed may cause an  
explosion. Do not expose any part of your body or clothing  
directly above cooking area when lighting.  
CAUTION  
SPIDER ALERT!  
1. From beneath the grill, place lighted wooden match up  
through lighter/ventilation hole in center of bottom.  
2. While holding match in place, turn control knob to lighting  
position. Grill will ignite.  
3. Observe burner flames through openings in heat distribution  
plate. Make sure burner ignites and stays lit on both sides.  
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 burner.  
4. Preheat grill for 6 minutes with lid closed. Using control  
knob on Regulator/Valve, adjust flame to desired height for  
cooking.  
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 grills burner tube obstructing the flow of  
gas to the burner. The backed-up gas can ignite in the burner tube.  
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  
burner tube should be removed from the grill and cleaned before  
use whenever the grill has been idle for an extended period.  
IF YOU EXPERIENCE THE FOLLOWING:  
1. Smell gas.  
2. Burner will not light.  
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 CYLINDER!  
1. Wait for grill to cool.  
2. Use a 12” pipe cleaner to clean out the burner tube.  
CAUTION  
If ignition does NOT occur in 5 seconds, turn the  
burner control 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  
Light burner. Make sure burner stays lit while rotating the  
Always check flame prior  
control knob from HIGH to LOW.  
to each use.  
High  
Low  
5
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Grill Maintenance  
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.  
- Allow grill to cool before cleaning. Frequency of cleaning is  
determined by how often grill is used.  
- DO NOT use self-cleaning oven to clean any grill part.  
Extreme heat would remove any chrome plating and cause  
premature rusting.  
• 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.  
- Meat drippings will solidify in bottom of grill after a few uses.  
This residue should be removed regularly. Failure to do so  
could cause overflow at bottom vent openings and increase  
the chance of a grease fire.  
- When cleaning grill, cover work area with newspaper.  
Remove grill lid and cooking grate. Loosen residue with  
scraper or putty knife. Wipe away loosened residue with  
paper towels.  
Before Cooking For The First Time  
Operate grill for 15 minutes with the grill lid closed and the gas  
control on HIGH. This will heat-clean internal components and  
eliminate odor from paint finish of grill.  
- Inside surface of grill may be cleaned with a strong solution  
of detergent and water applied with a scrub brush. Cooking  
grate may be cleaned with a wire brush. Thoroughly rinse  
grill with water and allow to completely air-dry before using  
again.  
Turning Grill Off  
- After cooking, turn the grill off by rotating the control knob to  
OFF. Control knob should pop up in the OFF position. If  
control knob does not pop up, disconnect cylinder to turn grill  
off and replace the Regulator/Valve.  
- Place cooking grate and lid onto grill.  
- Allow grill to cool completely before storing.  
Food Safety  
Storing Grill  
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:  
- Allow grill to cool completely.  
- Remove Propane Cylinder and install protective cap over  
outlet threads.  
- Remove Regulator/Valve from grill to help keep dirt out of the  
propane cylinder probe.  
Clean: Wash hands, utensils, and surfaces with hot soapy  
water before and after handling raw meat and poultry.  
- Store Regulator/Valve in a heavy plastic bag and place inside  
grill.  
- Fold legs up over top of grill with lid in closed position.  
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 klil 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 (202)  
720-3333, 10:00 am-4:00 pm EST.  
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LIMITED WARRANTY  
This warranty only applies to units purchased from an authorized retailer. Manufacturer warrants to the original consumer-purchaser only that this  
product shall be free from defects in workmanship and materials after correct assembly and under normal and reasonable home use for the periods  
indicated below beginning on the date of manufacture*. The manufacturer reserves the right to require that defective parts be returned, postage and or  
freight pre-paidbythe consumer for review andexamination.  
SCOPE OF COVERAGE  
ALL PARTS  
PERIOD OF COVERAGE  
90 DAYS  
TYPE OF FAILURE COVERAGE  
PERFORATION, MANUFACTURING,  
AND MATERIAL DEFECTS ONLY  
*Note: The warranty period of coverage will be extended to begin on the date of purchase on the condition that the consumer registers the product  
and supplies a copy of the original dated sales receipt.  
The original consumer-purchaser will be responsible for all shipping charges for parts replaced under the terms of this limited warranty.  
This limited warranty is applicable in the United States and Canada only, is only available to the original owner of the product and is not transferable.  
Manufacturer requires proof of your date of purchase. Therefore, you should retain your sales slip or invoice. Registering your product is not a  
substitute for proof of purchase and the manufacturer is not responsible for or required to retain proof of purchase records.  
This limited warranty applies to the functionality of the product ONLY and does not cover cosmetic issues such as scratches, dents, corrosions or  
discoloring by heat, abrasive and chemical cleaners or any tools used in the assembly or installation of the appliance, surface rust, or the  
discoloration of stainless steel surfaces.  
This limited warranty will not reimburse you for the cost of any inconvenience, food, personal injury or property damage.  
ITEMS MANUFACTURER WILL NOT PAY FOR:  
1. Shipping cost, standard or expedited, for warranty and replacement parts  
2. Service calls to your home.  
3. Repairs when your product is used for other than normal, single-family household or residential use. 4.Damage, failures, or  
operating difficulties resulting from accident, alteration, careless handling, misuse, abuse, fire, flood, acts of God, improper  
installation or maintenance, installation not in accordance with electrical or plumbing codes, or use of products not approved by the  
manufacturer.  
5. Any food loss due to product failures or operating difficulties.  
6. Replacement parts or repair labor costs for units operated outside the United States or Canada.  
7. Pickup and delivery of your product.  
8. Repairs to parts or systems resulting from unauthorized modifications made to the product.  
9. The removal and/or reinstallation of your product.  
DISCLAIMER OF IMPLIED WARRANTIES and LIMITATION OF REMEDIES  
Repair or replacement of defective parts is your exclusive remedy under the terms of this limited warranty. Manufacturer will not be responsible for  
any consequential or incidental damages arising from the breach of either this limited warranty or any applicable implied warranty, or for failure or  
damage resulting from acts of God, improper care and maintenance, grease fire, accident, alteration, replacement of parts by anyone other than  
Manufacturer, misuse, transportation, commercial use, abuse, hostile environments (inclement weather, acts of nature, animal tampering), improper  
installation or installation not in accordance with local codes or printed manufacturer instructions.  
THIS LIMITED WARRANTY IS THE SOLE EXPRESS WARRANTY GIVEN BY THE MANUFACTURER. NO PRODUCT PERFORMANCE  
SPECIFICATION OR DESCRIPTION WHEREVER APPEARING IS WARRANTED BY MANUFACTURER EXCEPT TO THE EXTENT SET  
FORTH IN THIS LIMITED WARRANTY. ANY IMPLIED WARRANTY PROTECTION ARISING UNDER THE LAWS OF ANY STATE,  
INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE, IS HEREBY  
LIMITED IN DURATION TO THE DURATION OF THIS LIMITED WARRANTY.  
Neither dealers nor the retail establishment selling this product has any authority to make any additional warranties or to promise remedies  
in addition to or inconsistent with those stated above. Manufacturer's maximum liability, in any event, shall not exceed the purchase price of the  
product paid by the original consumer.  
NOTE: Some states do not allow an exclusion or limitation of incidental or consequential damages, so some of the above limitations or exclusions  
may not apply to you. This limited warranty gives you specific legal rights as set foth herein. You may also have other rights which vary from state  
to state. In the state of California only, if refinishing or replacement of the product is not commercially practicable, the retailer selling this product or  
the Manufacturer will refund the purchase price paid for the product, less the amount directly attributable to use by the original consumer-purchaser  
prior to discovery of the nonconformity. In addition, in the state of California only, you may take the product to the retail establishment selling this  
product in order to obtain performance under this limited warranty.  
If you wish to obtain performance of any obligation under this limited warranty, you should  
write to:  
Consumer Relations  
P. O. Box 1240  
Columbus, GA 31902-1240  
Consumer returns will not be accepted unless a valid Return Authorization is first acquired. Authorized returns are clearly marked on the outside of  
the package with an RA number and the package is shipped freight/postage pre-paid. Consumer returns that do not meet these standards will be  
refused.  
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Parts List  
Key Qty Description  
A
B
C
D
E
F
G
H
I
1
1
2
1
1
1
1
1
2
1
2
Lid Handle  
Lid  
Lid Support Bracket  
Cooking Grate  
Heat Distribution Plate  
Burner  
Heat Resistant Shield  
Bottom  
Side Handle  
Regulator/Valve  
Leg  
J
K
Not Shown  
1
1
Hardware Pack  
Assembly Instructions, English  
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.  
Tools required for assembly:  
Adjustable Wrench - Not provided  
Phillips screwdriver - Not provided  
Hardware  
Hardware is shown actual size.  
(L)  
(M)  
(N)  
#10-24 Flange Nut  
Qty. 8  
(O)  
#10-24 x 3/4” Screw  
Qty. 4  
(P)  
#10-24 x 3/8” Screw  
Qty. 4  
(Q)  
1/4” Flat Washer  
Qty. 2  
Fiber Washer  
Qty. 6  
1/4-20 x 3/8” Screw  
Qty. 3  
8
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Assembly  
1
BURNER (F)  
- Position Heat Shield (G) as shown at right below and place into  
Bottom (H).  
HEAT RESISTANT SHIELD (G)  
- Insert narrow end of Burner (F) through large hole in side of Bottom  
(H) and rest burner bracket on Shield (G).  
- Insert one 1/4-20 x 3/8” Screw (M) through Bottom (H), Shield (G)  
and into burner bracket.  
BOTTOM (H)  
CAUTION  
Some parts may contain sharp edges! Wear protective  
gloves if necessary.  
1/4-20 x 3/8” SCREW (M)  
2
- Position Legs (K) as shown at right.  
- Spread ends of Legs (K) slightly and insert into holes in front and  
rear of Bottom (H).  
LEG (K)  
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Assembly (Con’t.)  
3
#10-24 x 3/4” SCREW (O)  
SIDE HANDLE (I)  
HEAT DISTRIBUTION PLATE (E)  
- Assemble Side Handles (I) to Bottom (H) using two each #10-24 x  
3/4” Screws (O), Fiber Washers (L) and #10-24 Flange Nuts (N)  
per Handle (I).  
- Rest the notches on ends of Heat Distribution Plate (E) on Side  
Handles Screws (O) inside Bottom (H).  
PLEASE NOTE: This table top propane gas grill has been designed  
to work effectively without the use of lava rocks. The reflective heat  
distribution plate efficiently vaporizes the food juices to add that  
great barbecue taste to your food. The plate also stays in place  
during transportation to eliminate the messy “set-up” required with  
lava rocks each time you use your grill.  
FIBER WASHER (L)  
#10-24 FLANGE NUT (N)  
4
- Attach Lid Handle (A) to Lid (B) using two each Fiber Washers (L), 1/4”  
Flat Washers (Q) and 1/4-20 x 3/8” Screws (M).  
NOTE: Fiber Washers (L) should be between Handle (A) and Lid (B).  
- Install Hinge Brackets (C) to inside of Lid (B) using two each #10-24 x  
3/8” Screws (P) and #10-24 Flange Nuts (N) per bracket. Make sure  
notches in Hinge Brackets (C) are toward the bottom edge of Lid (B) and  
are facing the same direction.  
#10-24 FLANGE NUT (N)  
LID HANDLE (A)  
FIBER WASHER (L)  
HINGE BRACKET (C)  
LID (B)  
- Place Cooking Grate (D) into Bottom (H).  
- Place Lid (B) onto Bottom (H).  
#10-24 x 3/8” SCREW (P)  
1/4” FLAT WASHER (Q)  
1/4 -20 x 3/8” SCREW (M)  
COOKING GRATE (D)  
10  
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Assembly (Con’t.)  
5
- Before assembly, inspect Regulator (J) for damage, dirt or debris  
accumulation. Clean out if present.  
- With knob pointing down, insert Regulator/Valve (J) into end of  
Burner (F).  
Notch in Regulator/Valve (J) MUST engage dimple in end of  
Burner (F).  
Rotate clockwise to lock  
- Once Regulator/Valve (J) has completely engaged Burner (F), turn  
Regulator/Valve (J) clockwise to lock in position with knob pointing  
up.  
Regulator/Valve (J)  
Regulator/Valve (J)  
Locked in position  
6
- Remove cap from end of Propane cylinder (sold separately). Cap  
should be kept on cylinder when not in use to prevent dirt and debris  
from entering Regulator/Valve (J). Check end of cylinder attachment  
for dirt and debris. Clean out if necessary.  
- Insert threaded end of Propane Cylinder into Regulator/Valve (J) and  
hand-tighten. DO NOT USE TOOLS! Over tightening can damage  
threads on Regulator/Valve (J).  
- Perform a leak test.  
Propane Cylinder  
(not included)  
11  
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EMERGENCIES: If a gas leak cannot be stopped, or a fire occurs due to gas leakage, call the fire department.  
Troubleshooting  
Prevention/Solution is turned on.  
Problem  
Possible Cause  
• Replace Cylinder.  
Burner will not Light.  
• Out of Propane  
• Retighten cylinder.  
• Regulator not fully tightened to cylinder.  
Inspect burner for obstructions.  
• See Care and Use’ for burner cleaning instructions.  
• See Care and Use’ section Before Cooking For The First Time’.  
Flames burns out on  
“LOW”.  
• Grill not sufficiently preheated before  
turning to LOW”.  
12  
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